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ACS600 Hardware Manual, ACS/ACC/ACP 604/607/627, Frequency

1. o X21 X22 cables 0 5 to 1 5 mm 20 to E 16 AWG S 5 X2 X23 X25 X26 X27 cables 0 5 to 2 5 mm S So 20 to 14 AWG Ss 85 85 36 Programmable I O Control Cable Lead through Size 02 208 Factory Settings 2 x 3x2 11 mm 0 08 to 0 43 S zz un x2 x21 Factory settings of application software zul a 1 VREF Reference voltage 10 V d c selection B type code wa 2 H 2 GND kG R 10ko Bu Put Stop DI3 Reverse 1 a ees 3 Alt Speed reference 0 2 10 V AA laine 4 4 AM Rin gt 200 kQ DI5 6 Constant speed 1 to 3 select IER E Ela Eee IMA ee y default not in use 1 Parameter 10 3 must be set to REQUEST 6 6 Jal 0 4 20 mA Ri 1000 A 7 Al3 By default not in use 2 Operation 0 Open 1 Closed 3 l 8 Tas 0 4 20 mA Ri 100 Q DIS DIG Output en e 9 p 9 AO1 Motor speed 0 4 20 mA2 0 O Set speed through Al 1 40 lasse 10 AO1 0 motor nom speed Hj lt 700 Q 1 O Constant Speed 1 A 11_ 11 AO2 Output current 0 4 20 mA 0 1 Constant Speed 2 j2 12 AO2 0 motor nom current R lt 700 Q 1 1 Constant Speed 3 X22 Connector X28 for RS 485 connection AS 13 1 DI1 Stop Start TRANS 14 2 DI2 Forward Reverse 1 2 GND 15 3 DI3 Not used 3 a Standard Modbus Link L c I ee 4 Di4 ACCEL DECE
2. Terminal Block X1 Function Terminal Block Size A 1 10 V Reference Voltage 10 VDC X1 X2 X4 X5 X8 cables 0 5 to 1 5 mm 2 AGND Analogue Ground X7 cables 0 5 to 2 5 mm 3 10V Reference Voltage 10 VDC Control Cable Lead through Size t 4 Ali External Reference 1 Speed Q 2x 3x2 11 mm Es 5 Al1 Reference Ex 6 Al2 External Reference 2 Not 7 Al2 defined en ail 3 Ur SPEED ACT 1 i 9 AO1 _1_ Terminal Block X2 P REM n 1 DI START STOP 2 DI2 Not defined 3 DI3 FAULT RESET 4 DI4 SPEED REF SW2 5 DI5 ACC DEC 1 2 SEL 6 DI6 7 DI7 Connector X300 for RS 485 connection 8 DI8 9 DI9 Not defined Standard Modbus Link 10 DI10 11 DI11 12 DI12 j 2 en Control Voltage Output HEN ge M 424 V d c max 135 mA 15 24 DV Connector shield is connected via RC filter to frame 16 DGND Digital Ground Terminal Block X4 1 24 V Auxiliary Voltage Output 2 DGND OV Terminal Block X5 1 24 DV Control Voltage Input 2 DO1 ACT SPEED 0 3 DO2 RUNNING 4 DO3 FAULT 1 AU 5 DO4 ACT SPEED REF 6 DGND Digital Ground Terminal Block X8 1 UENC Power Supply 2 SENSE Sense 3 SENSE Sense 4 UENC OV 5 A Channel A 6 A Channel A if B Channel B x 8 B Channel B 9 Z Channel Z 10 Z Channel Z l Terminal Block X7 1 RO1 NCC 2 RO1 CM 1 Relay Output READY Signal amp 3 RO1 NOC ACS ACC ACP 604 6x7 Frequency Converters A 13 NIOC Board Chaining
3. ES A f MUN 4 E Z 1 E TORE 2 s 8 NAT z z Y 7 b i 270 2108 1 ECC l rm E e Light Common Mode Filter eee Code 64315439 B ACS ACC ACP 604 6x7 Frequency Converters 3 11 Chapter 3 Electrical Installation Mains and Motor Cable Connections Transformer Settings 1 Connect the phase conductors of the mains cable to the U1 V1 and W1 terminals and the phase conductors of the motor cable to the U2 V2 and W2 terminals 2 Check that the earthing is still OK 3 Close the hinged assembly plate 1 ACx 604 607 units except frame R7 units include a transformer T41 which supplies power to the cooling fan at the base of the converter unit The transformer is set to 415 V 500 V or 690 V at the factory Adjust the setting if it does not correspond to the supply voltage To access the transformer remove the front cover of the converter unit with the ABB logo After adjusting the voltage put the plate back into its place Cabinets with the line contactor option include an internal auxiliary voltage transformer Its input voltage is set to 415 V 500 V or 690 V at the factory Adjust the setting if it does not correspond to the supply voltage The transformer is located in the upper right part of the cabinet and is visible when the cabinet door is opened 3 1
4. Requirement for 9 Motor Type Nominal Mains 3 Voltage ACS 600 du dt Filter Insulated N end bearing and ACS 600 Common Motor Mode Filter E Insulation 3 System Py lt 100 kW 100 kW lt Py lt 350 kW Py gt 350 kW and or Frame Size lt IEC 315 Frame Size gt IEC 315 A Random UN lt 500 V Standard N N CMF B wound V V B M2 andM3 500 V Uy 600 Standard du dt du dt du dt N LCMF or Reinforced z N N CMF 600 V lt Uy lt 690 V Reinforced du dt du dt du dt N LCMF Form wound 380 V lt Un lt 690 V Standard n a N CMF N CMF HXR and AM_ Old form 380 V lt Uy lt 690 V Check with the du dt filter with voltages over 500 V N CMF wound HX_ motor and modular manufacturer Random 380 V lt Uy lt 690 V Check with the du dt filter with voltages over 500 V N CMF wound HXR motor manufacturer N Random UN lt 420 V Standard N or CMF N CMF O wound and UL 1300 V N form wound 420 y lt Uy lt 500 V Standard du dt du dt N du dt N CMF A OL 1300 V n B du dt CMF B or Reinforced Nor CMF N CMF UL 1600 V 0 2 microsecond rise time 500 V lt Uy lt 600 V Reinforced du dt du dt du dt N LCMF Uj 1600 V or Reinforced N or CMF N CMF UL 1800 V 600 V lt Uy lt 690 V Reinforced du dt du dt du dt N LCMF U 1800 V Form wound 600 V lt UN 690 V Reinforced n a N
5. Positioning point to point positioning Synchronising positioning to moving target User macro 1 amp 2 user s own customised parameter settings Crane Crane normal crane drive Master Follower two crane drive applications with Master Follower Control operation User macro 1 amp 2 user s own customised parameter settings Decanter Decanter separating solid particles from liquids Centrifuge Extruder Extruder Hand Auto extruder drives PID Control Torque Control Sequential Control User macro 1 amp 2 Centrifuge Centrifuge centrifuge drives Traverse Traverse textile machines Control A 24 ACS ACC ACP 604 6x7 Frequency Converters Macro Language Combinations Appendix A ACS ACC ACP 604 6x7 Technical Data Languages and application macros included in each ACx 600 application program are shown below Not all selections are available for all types Application Program Type code Application Macros Languages character no 15 Standard B Factory Hand Auto PID Control English UK amp Am French Spanish Torque Control Sequential Control Portuguese EG Factory Hand Auto PID Control Torque Control Sequential Control English UK amp Am German Italian Dutch D Factory Hand Auto PID Control English UK amp Am Danish Swedish Torque Control Sequential Control Finnish E Factory Hand Auto PID Control English UK amp Am Fr
6. Installation checks Dimensional drawings ACS ACC 624 Drive Modules Supplement EN 64186477 included in ACx 624 module deliveries only Safety instructions Technical data Dimensional drawings SUPPLY SECTION MANUALS with 630 to 3000 kW units depending on the supply type one of these manuals is included in the delivery Diode Supply Sections User s Manual DSU EN 61451544 DSU specific safety instructions DSU hardware and software descriptions DSU commissioning Earth fault protection options Thyristor Supply Sections User s Manual TSU EN 64170597 TSU operation basics TSU firmware description TSU program parameters TSU commissioning FIRMWARE MANUALS FOR DRIVE APPLICATION PROGRAMS appropriate manual is included in the delivery Standard EN 61201441 Control Panel use Standard application macros with external control connection diagrams Parameters of the Standard Application Program Fault tracing Fieldbus control ote a separate Start up Guide is attached Motion Control EN 61320130 Control Panel use Start up Operation Parameters Fault tracing Fieldbus control Crane Drive EN 3BSE 011179 Commissioning of the Crane Drive Application Program Control Panel use Crane program description Parameters of the Crane Drive Application Program Fault tracing Pump and Fan Control PFC EN 61279008 Control Panel use Application macros Parameters
7. ACS ACC ACP 604 6x7 Frequency Converters A 9 Appendix A ACS ACC ACP 604 6x7 Technical Data NIOC Board External control connections of NIOC board for ACS 600 with Standard Application Software Factory Macro are shown below For the connections of other application macros and programs see Firmware Manual N 8 SY oo ro oa uh Oo Programmable I O Q g a Factory Settings Terminal Block Size X21 2 X21 X22 cables IB 1 5 mm 20 to 16 AWG c 1 VREF Reference voltage 10 V d c X23 X25 X26 X27 cables 0 5 to 2 5 mm 20 to 2 GND 1kQ R 10kO 14 AWG z Control Cable Lead through Size 3 Alt Speed reference 0 2 10 V D 2x 3x2 11 mm 4 AN Rin gt 200 kQ EL 5 Al2 By default not in use 6 Al2 0 4 20 mA Ri 100 Q 7 Al3 By default not in use 8 AI3 0 4 20 mA Ri 100 Q Factory settings of application software con 9 AO1 Motor speed 0 4 20 mA selection B type code 10 AO1 0 motor nom speed Hj lt 700 Q DI1 Start DI2 Stop DI3 Reverse D14 A 11 AO2 Output current 0 4 20 mA Acc Dec 2 DI5 6 Constant speed 1 to 3 select 12 ao2 0 motor nom current
8. 0140 3 0170 5 0140 6 1250 49 2 462 524 407 16 135 297 v gu 0170 6 18 19 20 63 0170 3 0210 5 0210 6 1250 49 2 462 524 407 16 140 308 18 19 20 63 W2 i7 0210 3 0260 5 0260 6 1250 49 2 462 524 407 16 140 308 sms i 18 19 20 63 uoc 0260 3 1600 63 462 524 407 16 166 365 18 19 20 63 0320 3 1600 63 462 524 407 16 166 365 bis 18 19 20 63 t 0320 5 0320 6 1600 63 462 524 407 16 171 376 18 19 20 63 TT 0400 5 0400 6 1600 63 462 524 407 16 171 376 DOI c III 0400 3 0490 5 0490 6 2 x Dimensions of ACx 604 0210 3 0490 3 0610 5 0610 6 2 x Dimensions of ACx 604 0260 3 0610 3 0760 5 0760 6 2 x Dimensions of ACx 604 0320 3 Width marked with does not include motor cable terminals PE terminal or DC bus terminals ACS ACC ACP 604 6x7 Frequency Converters A 21 Appendix A ACS ACC ACP 604 6x7 Technical Data Dimensions and Dimensions and weights of the ACx 6x7s are given below Weights ACx 6x7 Height Width Depth Weight ACx 6x7 Type mm in mm in mm in kg Ibs 0100 3 0120 5 0100 6 2078 23162 830 644 275 300 81 8 91 2 32 7 25 35 605 660 0120 3 0140 5 0120 6 2078 23162 830 644 275 300 81 8 91 2 32 7 25 35 605 660 0140 3 0170 5 0140 6 0170 6 20781 2316 830 12309 644 340 3909 81 8 91 2 32 7
9. CMF N CMF UL 2000 V 0 3 microsecond rise time manufactured before 1992 ACS ACC ACP 604 6x7 Frequency Converters ACx ACS ACC ACP ix Safety Instructions Note 1 The abbreviations used in the table are defined below Abbreviation Definition UN nominal mains voltage UL peak line to line voltage at motor terminals which the motor insulation must withstand PN motor nominal power du dt du dt filter CMF common mode filter 3 toroidal cores per each motor cable LCMF light common mode filter 1 toroidal core per each motor cable N N end bearing insulated motor non driven end bearing n a Motors of this power range are not available as standard units Consult the motor manufacturer Note 2 ACA 635 IGBT Supply Sections and the ACS ACC 611 If voltage is raised by the ACA 635 or the ACS ACC 611 select the motor insulation system according to the increased intermediate circuit d c voltage level especially in the 500 V 41096 supply voltage range Note 3 HXH and AMA Motors All AMA machines manufactured in Helsinki to be supplied by a frequency converter have form wound windings All HXR machines manufactured in Helsinki since 1997 have form wound windings Note 4 Chopper Resistor Braking When the drive is in braking mode for a large part of its operation time the intermediate circuit DC voltage of the drive increases the effect being similar to increasing the supply vol
10. AZ V or 500 V ACS 604 607 0120 5 164 110 R7 ACS 604 607 0140 5 193 132 ACS 604 607 0170 5 240 160 R8 ACS 604 607 0210 5 285 200 ACS 604 607 0260 5 345 250 ACS 604 607 0320 5 460 315 R9 ACS 604 607 0400 5 490 1400 335 ACS 6x4 6x7 0490 5 656 450 2xR8 ACS 6x4 6x7 0610 5 874 630 2xR9 ACS 6x4 6x7 0760 5 990 710 Normal use 10 overload capacity The current ratings are the same regardless of the supply voltage within one voltage range The rated current of the ACx 60x must be higher than or equal to the rated motor current to achieve the rated motor power given in the table Note 1 The maximum allowed motor shaft power is limited to 1 5 Pha If the limit are exceeded the motor torque and the lohdmax 2 15 s current is automatically restricted The function protects the input bridge of the ACS 600 against overload Note 2 The load capacity current and power decreases if the installation site altitude exceeds 1000 metres or if the ambient temperature exceeds 40 C or 35 C with ACx 60x 0120 03 and ACx 60x 0140 05 units in Pump and Fan Use See Output Current Temperature Derating on page A 3 Note 3 The Pump and Fan rating is not to be used with du dt filters du dt filters are usually needed at the output of 525 V to 690 V units with random wound motors No du at filters are usually required with form wound motors Notes concerning Pump and Fan Use only Pump and Fan rating is available for ACS 600
11. In 690 V units 2 kHz average Maximum Recommended Motor Cable Length 300 m 980 ft This is the cumulative length in case of parallel connected motors For ACx 601 0005 3 to ACx 601 0016 3 ACx 601 0006 5 to ACx 601 0020 5 and ACx 601 0009 6 to ACx 601 0020 6 if the motor cable length exceeds 70 metres 230 ft an ABB representative should be consulted Bearings of over 90 kW 125 HP Motors Insulated bearing at non driven end is recommended A 4 ACS ACC ACP 604 6x7 Frequency Converters Efficiency and Cooling Ambient Conditions Appendix A ACS ACC ACP 604 6x7 Technical Data Efficiency Approximately 98 at nominal power level Cooling Method Internal fan flow direction from the bottom to the top Environmental limits of the ACS ACS ACP 600 frequency converters are given below The frequency converters are to be used in a heated indoor controlled environment ACS ACC ACP 600 Operation installed for stationary use Storage in the protective package Transportation in the protective package Installation Site Altitude Nominal output power at 0 to 1000 m 3300 ft above sea level 1 Air Temperature 0 to 40 C 32 to 104 F IP 21 22 and ACx 607 IP 54 0 to 25 C 32 to 77 F 2 ACx 601 IP 54 40 to 70 C 40 to 158 F 40 to 70 C 40 to 158F Relative Humidity 5 to 95 Max 9596 Max 9596 No condensation allowed Maximum allowed
12. R lt 700 Q x22 a a Tp Stop Start 1 If Par 10 3 is REQUEST 2 DI2 Forward Reverse 3 DI3 Not used 2 Operation 0 Open 1 Closed TT 4 DM ACCEL DECEL 1 2 DI5 DI6 Output lt 5 Tps Constant speed select 0 O Set speed through Alt lt 6e De Constant speed select 1 0 Constant Speed 1 7 24V 24 V d c max 100 mA 0 1 Constant Speed 2 8 24V 1 1 Constant Speed 3 9 DGND Digital Ground X23 bia sca o de a a 1 24 V Auxiliary voltage output non isolated 2 GND 24 V d c 250 mA Standard Modbus Link X25 1 RO11 Relay output 1 2 RO12 Ready amp 3 RO13 X26 Connector X29 for RS 485 connection RO21 Standard Modbus Link 2 RO22 Relay outputa Q 3 RO23 Running X27 amp 1 R031 Relay output 3 Fault 2 R032 Fault 1 3 R033 Connector shield is connected via RC filter to frame A 10 ACS ACC ACP 604 6x7 Frequency Converters Appendix A ACS ACC ACP 604 6x7 Technical Data Optional Terminal Block External connections to optional terminal block X2 for ACS 600 X2 Standard Application Program Factory Macro are shown below For the connections of other application macros and programs see Firmware Manual Terminal Block Size
13. 1 Traverse English This selection is for the North American market The default parameter settings in the standard application macros include minor changes to fulfil the local regulations such as 3 wire start stop Standard Application Program version 6 x includes MASTER FOLLOWER Parameter Group and the following languages Czech Danish Dutch English UK amp Am Finnish French German Italian Polish Spanish Swedish Portuguese PFC Application Program version 6 x includes the following languages Czech Danish Dutch English UK amp Am Finnish French German Italian Polish Spanish Swedish Portuguese ACS ACC ACP 604 6x7 Frequency Converters A 25 Appendix A ACS ACC ACP 604 6x7 Technical Data Protection Features Application program dependent features of the ACx 600 are listed below e available as standard o optional Not all selections are available for all types For more information refer to the appropriate application program Firmware Manual 9 2 g Preprogrammed pu E Programmable pu t Programm 2 E P Faults ES s 8 E Fault Functions E 5 8 E Supervision ES E SES g o c g Functions 52 2 ACx 600 temperature e e Analogueinputbelow e Speed 2 2 2 minimum value Overcurrent e e Loss of Control Panel e e e Motor curr
14. 11502 490 400 500 Three phase supply voltage 380 V 400 V 415 V 440 V 460 V 480 V or 500 V ACx 604 607 0120 5 135 149 120 90 100 112 168 112 224 100 75 75 R7 ACx 604 607 0140 5 164 180 140 110 125 135 203 135 270 120 90 100 ACx 604 607 0170 5 200 220 170 132 150 164 246 164 328 140 110 125 R8 ACx 604 607 0210 5 240 264 210 160 200 200 300 200 400 170 132 150 ACx 604 607 0260 5 300 330 260 200 250 240 360 240 480 210 160 200 ACx 604 607 0320 5 365 402 320 250 300 300 450 300 600 260 200 250 R9 ACx 604 607 0400 5 460 506 400 315 350 365 548 365 730 320 250 300 ACx 604 6x7 0490 5 570 627 490 400 500 456 684 456 912 400 315 400 2xR8 ACx 604 6x7 0610 5 694 764 610 500 600 570 855 570 11140 490 400 500 2xR9 ACx 604 6x7 0760 5 874 961 760 630 700 694 1041 694 11388 610 500 600 Three phase supply voltage 525 V 550 V 575 V 600 V 660 V or 690 V ACx 604 607 0100 6 88 97 100 75 100 65 98 65 98 70 55 75 R7 ACx 604 607 0120 6 105 116 120 90 125 88 132 88 132 100 75 100 ACx 604 607 0140 6 127 140 140 110 150 105 158 105 158 120 90 125 R8 ACx 604 607 0170 6 150 165 170 132 1
15. 3 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 It is not allowed to install an ACx 604 6x7 with the EMC Filter options code 0 or 3 in the type code for EMC Filters to unearthed mains an ungrounded power system or a high resistance grounded power system over 30 ohms The mains will be connected to earth potential through the EMC filter of the ACx 600 which may cause danger or damage the unit Disconnect the EMC filter capacitors before connecting the ACx 600 to unearthed mains For detailed instructions on how to do this please contact your local ABB distributor The motor must not be controlled with the supply disconnecting device instead the and keys of the Control Panel or commands via the digital inputs NIOC board or serial communication NAMC board of the ACx 600 should be used The maximum number of charging cycles of the d c capacitors of ACx 600 i e power ups by applying the input power is five in ten minutes WARNING Never connect the mains line power to the ACx 600 output If frequent bypassing is required employ mechanically connected switches or contactors that prevent simultaneous connection of the motor to the supply network and to the output of the ACx 600 Mains line voltage applied to the output can result in permanent damage to the unit Operation outside the nominal voltage range should
16. 3 1 Chapter 3 Electrical Installation Input Cable Protection Cabling Instructions Power Cables Normal slow fuses can be used to protect the input cable in case of a short circuit They do not protect the input bridge of ACx 600 in case of a short circuit Slow fuses must be dimensioned according to local safety regulations appropriate mains voltage and the rated current of the ACx 600 see Appendix A ACS ACC ACP 604 6x7 Technical Data The mains and motor cables must be dimensioned according to local regulations 1 The cable must be able to carry the ACx 600 load current 2 The cable terminals of ACx 600 warm up to 60 C 140 F during operation The cable must be rated for at least 60 C 140 F maximum operating temperature 3 The cable must fulfil the requirements of the short circuit protection used 4 The inductance and impedance of the cable must be rated according to permissible touch voltage appearing under fault conditions so that the fault point voltage will not rise too high when an earth fault occurs The voltage rating of the mains cables should be 1 kV for 690 VAC rated equipment For the North American market 600 VAC rated cable is accepted for 600 VAC rated equipment Voltage rating for the motor cables should be minimum 1 kV as a general rule Symmetrical shielded motor cable must be used figure below Four conductor system is allowed for mains cabling but shielded symmetrical ca
17. 480 V 500 V and 600 V ranges ACS 604 x pending pending 480 V 500 V and 600 V parallel connected units 1 the approval is valid up to 600 V ACS 600 is suitable for use in a circuit capable of delivering not more than 65 kA rms symmetrical amperes at 480 V maximum 500 V units and at 600 V maximum 690 V units ACS 600 provides overload protection in accordance with the National Electrical Code US See ACS 600 Firmware Manual for setting Default setting is off must be activated at start up ACS 600 drives are to be used in a heated indoor controlled environment See subsection Ambient Conditions for specific limits ACS 600 braking chopper ABB has braking chopper modules that when applied with appropriately sized braking resistors will allow the drive to dissipate regenerative energy normally associated with quickly decelerating a motor Proper application of the braking chopper is defined in the NBRA 6xx Braking Choppers Installation and Start Up Guide Appendix A These guide lines will allow you to size braking choppers to your specific application needs for standard or extended duty cycles This can be applied to a single drive or multiple drives with DC Bus connected to allow a sharing of regenerative energy C tick marking is required in Australia and New Zealand A C tick mark is attached to ACx 601 607 frequency converters to verify that the unit follows the provisions of Radiocommunications Electro
18. 6x7 type code Code characters is given in the table below Not all selections are available for all types More information on selections is given in ACS 600 SingleDrive Ordering Information guide code 58977985 available on request Character Meaning Refer to no Example ACS60701003000B1200901 1 Product Category A AC Drive 2 3 Product Type CS Standard CC Crane Drive CP MotionControl 4 Product Family 6 ACS 600 5 Input Bridge 0 6 pulse rectifier 2 12 pulse rectifier 7 Regenerative 4Q thyristor bridge 6 Construction 1 Wall mounted 4 Module 7 Cabinet 7 10 Power Rating kVA Appendix A Ratings 11 Voltage Rating 3 380 400 415 V a c 4 380 400 415 440 460 480 500 V a c 5 380 400 415 440 460 480 500 V a c 6 525 550 575 600 660 690 V a c 12 14 Option 1 Option 2 Option 3 15 Application Software Appendix A x Languages and Application Macro Options Application Programs 16 Control Panel 0 None 1 Control Panel included 4 Customer I O Terminal Block X2 5 1 4 1 2 ACS ACC ACP 604 6x7 Frequency Converters Chapter 1 Introduction Character Meaning Refer to no 17 Degree of Protection Appendix A 0 IP 00 chassis A IP 21 2 IP 22 4 IP 42 Enclosures 5 IP 54 6 IP 00 with Coated Boards 7 IP 22 with Coated Boards 8 IP 42 with Coated Boards 9 IP 54 with Coated Boards B IP 21 with Coated Boards 18 Line Input and Protection Options 19 S
19. ACx 600 A 28 ACS ACC ACP 604 6x7 Frequency Converters Appendix A ACS ACC ACP 604 6x7 Technical Data Table A 1 The EMC filtering of the ACx 600 units is marked in the type code as follows du dt Filters EMC Filters du dt Filters No EMC Filters Type Code ACS 600 Type Character no EMC Filter No EMC Filter Selections Selections ACS ACC ACP 604 ACXXXXXXXXXXXXXXXXXXXX 0 9 20 ACS ACC ACP 6x7 ACXXXXXXXXXXXXXXXXXXXX 0 3 5 9 55 to 630 kW A 20 Public Low Voltage Network Unearthed Mains IT Network Medium voltage network Supply transformer Neighbouring network Static screen Point of measurement Low voltage Equipment victim ACx 600 Equipment Equipment Use of the ACx 600 in Second Environment without EMC filtering EN 61800 3 second environment includes all establishments other than those directly connected to a low voltage power supply network which supplies buildings used for domestic purposes 1 The ACx 600 is equipped with EMC filtering refer to Table A 1 2 The ACx 6x7 is installed according to the instructions given in this manual 3 The motor and control cables are selected as specified in this manual 4 Maximum cable length is 100 metres Without considering the EMC requirements do not use the ACx 600 on a low voltage public network
20. Appendix A ACS ACC ACP 604 6x7 Technical Data When several NIOC boards are daisy chained for common control from an external Modbus device the bus termination switch SW1 must be set on the participating boards as shown below NIOC SW1 NIOC wi NIOC NIOC No 1 ON No2 a No 3 Fwi No 4 a In HI n DI OFF ON U 7 IM xx d LI L L x293 E Drive units at a common earth potential e g installed in the same cabinet RS 485 Note When drive units are not at a common earth potential or long i distance connection is required NBCI modules can be used Refer to the mu board should have Modbus module manual SW1 in the OFF position if the external Modbus device has a bus termination lt Straight through cable Ident Grey circuit If in doubt set SW1 mc i to ON here Settings of Function Switch SW1 NAMC Ei Ei mm Ba gegen E OFF EJ Termination OFF off lt on NIOC oL ooo joo pou a Lg OFF Termination ON default ACS ACC ACP 604 6x7 Frequency Converters NIOC and NIOCP Board Specifications Appendix A ACS ACC ACP 604 6x7 Technical Data Data of the external control connection boards of the ACS 600 product family are given below ACS ACC ACP 600 NIOC 01
21. DI1 Start DI2 Stop DI3 Reverse DI4 Acc Dec 2 DI5 6 Constant speed 1 to 3 select 1 Parameter 10 3 must be set to REQUEST 2 Operation 0 Open 1 Closed DI5 DI 6 Output 0 0 Set speed through AI 1 Constant Speed 1 Constant Speed 2 1 0 1 0 1 1 Constant Speed 3 Connector X28 for RS 485 connection 1 TRANS GND B A GND o aj BY j N 24V Standard Modbus Link Connector X29 for RS 485 connection 1 TRANS FAULT B A or A j N GND 6 24V Standard Modbus Link Connector shield is connected via RC filter to frame o o S E 8 o Se 53 e 85 36 Programmable I O n o A Q 3 Q 9 q Factory Settings 2TB X21 A 1 VREF Reference voltage 10 V d c 7 Do i Peer 2 GND 1kQ lt R 10 ko D 3 Inn 3 Alt Speed reference 0 2 10 V Axe pa 4 A An gt 200 KQ 5 5 Al2 By default not in use 6 kso 6 Al2 0 4 20 mA Ri 100 Q Yo pe 7 Al3 By default not in use diste 8 AI 0 4 20 mA R 1000 con E 9 I 9 AO1 Motor speed 0 4 20 mA 10 x 10 AO1 0 motor
22. Earth the other end of the mains cable screen at the distribution board Earth the motor cable screen 360 degrees on the motor side Connect the additional PE conductors if present of the mains and motor cables to the PE terminal of the cabinet Connect the separate PE conductor if used to the PE terminal of the cabinet 3 10 ACS ACC ACP 604 6x7 Frequency Converters Chapter 3 Electrical Installation Common Mode Filter If common mode filter or light common mode filter is required see Safety Instructions Motor Connections Requirements Table lead the motor cable phase conductors through the toroidal cores as follows 1 Connect the twisted cable screen to the PE terminal 2 Wrap the phase conductors together with the silicon rubber tape delivered with the toroidal cores to provide thermal insulation for the conductor insulator Cover the part of the cable which will be left inside the core s 20 mm below Approximately 1 5 metres of tape is needed per cable Each turn must overlap the previous turn by half the width of the tape 3 Bind the conductors tightly with non conductive electrical tape and a non metallic cable tie in order to prevent conductor insulation damage caused by the core edges 4 Slide the core s onto the taped part of the phase conductors Bind the cores together and onto the taped part of the phase conductors with heat resisting non metallic cable ties VEY
23. Four Programmable Digital Outputs Short circuit proof Overload protection Maximum Load 10 mA with internal 24 V supply 100 mA with external supply Output Updating Time 2 ms A 16 ACS ACC ACP 604 6x7 Frequency Converters Appendix A ACS ACC ACP 604 6x7 Technical Data ACS ACC ACP 600 NIOC 01 Board ACP 600 NIOCP 01 Board Relay Outputs Three Programmable Relay Outputs One Relay Output Switching Capacity 8 A at 24 VDC or Switching Capacity 8 A at 24 VDC or 250 VAC 0 4 A at 120 VDC 250 VAC 0 4 A at 120 VDC Minimum Continuous Current 5 mA rms at Minimum Continuous Current 5 mA rms at 24 VDC 24 VDC Maximum Continuous Current 2 A rms Max Continuous Current 2 A rms Contact Material Silver Cadmium Oxide Contact Material Silver Cadmium Oxide AgCdO AgCdO Isolation Test Voltage 4 kVAC 1 minute Isolation Test Voltage 4 kVAC 1 minute Output Updating Time 100 ms ACS 600 Output Updating Time 2 ms 44 ms ACC 600 8 ms ACP 600 DDCS Fibre Optic Protocol DDCS ABB Distributed Drives Communication System Link Modbus RS 485 er Transmission Rate Max 9600 bit s Parity Selectable Connectors Shielded modular telecommunication socket Encoder Input One Encoder Input 3 channel differential frequency lt 200 kHz supply cable resistance compensation COMBICON connector 10 pins Meets the EIA standard RS 422 Encoder supply 5 VDC 10 VDC short circuit proof max 150 mA R
24. See dimensional drawings cable ACS ACC ACP 607 627 Dimensional Drawings routing inside the cabinet start up Start up Guide for ACS 600 Standard Application Program If the ACx 600 is equipped with another application program see the appropriate Firmware Manual ACx 604 modules and 624 Converter Module Installation in User defined Cabinet modules from 315 to 700 kW ACx 624 modules from 75 to ACS ACC 624 Drive Modules Supplement 315 kW optional equipment their manuals programming the unit the appropriate Firmware Manual ACS ACC ACP 604 6x7 Frequency Converters 1 1 Chapter 1 Introduction Delivery Check Check that there are no signs of damage Before attempting installation and operation check the information on the frequency converter nameplate to verify that the unit is of the correct model Each ACx 600 is fitted with a nameplate for identification purposes The nameplate data includes a type code and a serial number which allow individual recognition of each unit The type code contains information on the properties and configuration of the unit The first digit of the serial number refers to the manufacturing plant The next four digits refer to the unit s manufacturing year and week respectively The remaining digits complete the serial number so that there are no two units with the same serial number ACx 6x4 6x7 Type The meaning of the main selections of the ACx 6x4
25. a as ye di A 13 NIOC Board Chaining seems sa Pa a Ea ess e oe ae e A 14 NIOC and NIOCP Board Specifications oooococccronoccr eee A 15 ENCODER SIgnalS oce hse mi a fie p ee a or ORO EX MOR EO Ete ew hee ak A 18 Enclosures Space Requirements 000 e eee eee eae A 19 Cooling Air Flow Requirements 2 24 52 ai on baw Sa daw traer BOs eee Sr ER ea ot A 20 Heat Losses and Noise Levels voe x RU RO MU A xa RR Rec IN pg Ed A 20 Dimensions and Weights AOx 604 lt 3 ie eite re ea tee Ad ERO RR CRUS A 21 Dimensions and Weights ACx 6X7 0 0 0 eee A 22 Braking Chopper DIMENSIONS 2 2 450 do m gus Xo P RO E re sue B Apo ausa died t A 23 Application Programs n uut uc ice ed ga t an RP EA AR PURUS an QS er UE d NOR a ALACRES Run acd A 24 Application Maer s adf EY RR EUER EP E pe Eee E Yee e ee A 24 Macro Language Combinations ie eb RE MERO ER Ba a wa Dies wa A 25 Protection Features zu prodesse eisernen A 26 Applicable Standards corsi oid ita Baar Pie avis Kex De wh ewe eek ee a A 27 Malerlals urine od bode a Den Mae Mr ue dtu ete rc te E do qvod bad dt ante A 27 Transportation POSITION ans se a a Rd quy rect etre qi EEG RC RR Dee 3 A 27 MI oes etas ues Eras Oe eM e a a ots dr eM o me A atio A 28 GE Marking undated scd ruo ae cmo mare Vias Side d dan 2 act aras su Et A 28 Compliance with the EMC Directive lllsleeeeeeleee eee A 28 Machinery Directive sare ta ar ono t een ac RU Cet ind A 30 IJ SE WAR
26. been stocked clean and dry It is recommended to reform the capacitors once a year ACS ACC ACP 604 6x7 Frequency Converters 5 1 Chapter 5 Maintenance Co How to check the converter age Reforming time nverters Stocked Non operational for Less Than Co 2 years nverters Stocked Non operational for 2 Years and Over A Converter serial number defines the week when the converter has been built 8 digit e g 18250125 1 denotes manufacturing country 1 Finland 8 manufacturing year 1998 25 manufacturing week and 0125 running manufacturing number 10 digit e g 1983200725 1 denotes manufacturing country 98 manufacturing year 32 manufacturing week and 00725 running manufacturing number The intermediate circuit of the converter is kept in its nominal voltage for the reforming time to wake up the capacitors The reforming time required depends on how long the converter has been stocked non operational Reforming time hours 6 1 5 3 2 1 0 I 0 1 2 3 4 5 6 Non operational time years Method 1 Method 2 Figure 5 1 Capacitor reforming time for Method 1 and Method 2 Switch the power on to the converter for a time given in Figure 5 1 Method 1 The converter wakes up its capacitors by itself Power the converters up once a year to keep the capacitors in operational condition Use Method 2 A or Method 2 B both
27. dia Protected against light sprays or splashing water from all directions water shall not enter the enclosure in harmful quantities 5 Dust protected dust shall not enter the enclosure in sufficient Protected against low pressure sprays of water from all directions quantity to interfere with satisfactory operation of equipment water shall not enter the enclosure in harmful quantities 6 Dust tight Protected against heavy seas on shipdecks or strong sprays of water from all directions water shall not enter the enclosure in harmful quantities T A Space requirement for the door opening 74 700 mm 27 6 in 2 x R8 and 2 x R9 N P2 800 mm 31 5 in R7 R8 and R9 we ACS ACC ACP 604 6x7 Frequency Converters Appendix A ACS ACC ACP 604 6x7 Technical Data Cooling Air Flow Cooling air flow requirements are given below Requirements equirement ACx 60x Flow 60x 604 6x7 m h ACx 60x 0100 3 0120 5 0100 6 660 ACx 60x 0120 3 0140 5 0120 6 660 ACx 60x 0140 3 0170 5 0140 6 0170 6 1640 ACx 60x 0170 3 0210 5 0210 6 1640 ACx 60x 0210 3 0260 5 0260 6 1640 ACx 60x 0260 3 0320 5 0320 6 1840 ACx 60x 0320 3 0400 5 0400 6 1840 ACx 6x7 0400 3 0490 5 0490 6 3580 ACx 6x7 0490 3 0610 5 0610 6 3980 ACx 6x7 0610 3 0760 5 0760 6 3980 Heat Losses and Heat losses and noise levels are given below
28. doped Ko e po S b ert eR bed as 5 1 PIGTOITIHD coe ee CRIME RO ADU IR CORDE Ro Res XU POR a ew oaa rere fa 5 1 Control Panel Connection res 5 5 LDAP PRECEPIT 5 5 Appendix A ACS ACC ACP 604 6x7 Technical Data IECABAHT dS sese du hen s la in odo oA nM M ro ran Bla E me A 1 NEMA Ratu nds i P A 3 Output Current Temperature Derating oocooooocccrno nes A 3 Input Power Connection armen ue wet eaten NEN Rura od al A 4 MOTOR COMMSCTON sida ox co OR ac at wate Rv ta CR lO EROR cd va CROCI E E Do Ob es b ra IRA A 4 Efficiency and Cooling nn N ern te des he pronus a ele adea rad lose A 5 Ambient Conditions s 5 243 re arra qot de RO oe ee See RAGA da AED sae A 5 FUSES 3 eren enikbex ets bac ede N totes te n date dea ER n e e E CI RU d C TR A 5 Example e cnc ood vip aperi rece CHR tk IE WOE oa Rw Pg S Mee S OU du LR LU ce A 7 CFD IO A t habea Ot oo tote a ese d ar Ae te eM M riri a a te A a Nd A 7 T erms us6d x 3a tato Borse Rr ban Gadd ieu iat ae dia ds fu Ra IY raa er A 7 Terminal Sizes and Tightening Torques 00 eee eee A 8 xviii ACS ACC ACP 604 6x7 Hardware Manual External Control Connection Diagrams 459p nRPBETMRRR VEG AA AA Sie eed A 9 NIOGBOSI OS ee nod tee Rod SU Ne ud iit aa Rie A 10 Optional Terminal Block X2 acota d gem eee Ia Se vede item A 11 Optional Terminal Block 2TB US Version 0 00 cc cece eee A 12 10 9 rcr caos
29. erode the bearing races The stress on motor insulation can be avoided by using optional ABB du dt filters du dt filters also reduce bearing currents To avoid damage to motor bearings insulated N end non driven end bearings and output filters from ABB must be used according to the following table In addition the cables must be selected and installed according to the instructions given in this manual Three types of filters are used individually or in combinations 1 optional ACS 600 du dt filter protects motor insulation system and reduces bearing currents ACS 600 common mode filter mainly reduces bearing currents ACS 600 light common mode filter mainly reduces bearing currents The common mode filter is composed of toroidal cores installed onto the motor cable The following table shows how to select the motor insulation system and when optional ACS 600 du dt filters insulated N end non driven end motor bearings and ACS 600 common mode filters are required The motor manufacturer should be consulted regarding the construction of the motor insulation and additional requirements for explosion safe motors Failure of the motor to fulfil the following requirements or improper installation may shorten motor life or damage the motor bearings viii ACx ACS ACC ACP ACS ACC ACP 604 6x7 Frequency Converters Safety Instructions
30. explained below for capacitor reforming if the converter has been stocked or non operational for two or more years WARNING The ACx 6x7 inverters must be reformed outside the cabinet 5 2 ACS ACC ACP 604 6x7 Frequency Converters Chapter 5 Maintenance Method 2A Capacitor reforming is realised by connecting a rectifier and a resistor circuit to the converter DC link The reforming circuit and component values for different voltages are given below See the reforming time from Figure 5 1 WARNING The converter supply must be disconnected while the reforming circuit is connected Disconnect from supply 1 35 U4 Converter Supply Voltage Recommended Components A R C 380 V lt U 415V SKD 82 16 220 Ohm 700 W 22 nF 2000 V 380 V lt U 500V SKD 82 16 470 Ohm 1200 W 22 nF 2000 V 525 V lt U41 lt 690 V SKD 82 16 680 Ohm 1700 W 22 nF 2000 V ACS ACC ACP 604 6x7 Frequency Converters 5 3 Chapter 5 Maintenance Method 2B Capacitor reforming is based on a DC power supply connected to A converter DC link Power supply current charges converter capacitors If power supply cannot limit the current voltage is increased gradually with e g 100 V steps Maximum recommended reforming current is 500 mA An appropriate reforming voltage is 1 35 V2 U The reforming circuit is shown below See reforming time from Figu
31. if the PE rail of the ACx 607 is not earthed J via a separate PE conductor or via cable screen Fr 3 used only if local safety regulations do not accept earthing of the ACx 607 and the motor merely through the cable screen Note Connecting the fourth conductor of the cable at the motor increases bearing currents thus causing extra wear 4 The NIOC NIOCP board is located inside the module in ACx 604 deliveries For minimum radio frequency interference RFI at the motor end earth the cable screen 360 degrees at the lead through or earth the cable by twisting the screen flattened width gt 1 5 length 3 8 ACS ACC ACP 604 6x7 Frequency Converters Chapter 3 Electrical Installation electrician The Safety Instructions on the first pages of this manual A WARNING This work should only be carried out by a qualified must be followed Negligence of these instructions can cause injury or death Frame Sizes H7 to R9 The mains and motor cables connect to the ACx 607 in the left part of the cabinet Mains motor and control cable lead through is from below or from above To locate the terminals see the dimensional drawings Appendix B To connect the mains and motor cables to the ACx 607 carry out the following procedure 1 Make sure that the ACx 607 is disconnected from the mains network during installation Wait for 5 minutes if the ACx 607 is already connected to the mains after disconnecting main
32. insulation of the assembly proceed in the following manner WARNING Insulation checks must be performed before connecting the ACx 600 to the mains Before proceeding with the insulation resistance measurements make sure that the ACx 600 is disconnected from the mains 1 Check that the motor cable is disconnected from the ACx 600 output terminals U2 V2 and W2 2 Measure the insulation resistances of motor cable and the motor between each phase and Protective Earth with measuring voltage 1 kV d c The insulation resistance must be higher than 1 MQ Fuses are needed to protect the input bridge of the ACx 600 in case of an internal short circuit The ACx 6x7 is equipped with internal input fuses introduced in Appendix A ACS ACC ACP 604 6x7 Technical Data The ACx 604 is not equipped with input fuses When installing the ACx 604 you must always connect the supply via ultrarapid fuses given in Appendix A ACS ACC ACP 604 6x7 Technical Data If a fuse is blown it must not be replaced with a normal slow fuse rated according to Appendix A ACS ACC ACP 604 6x7 Technical Data An ultrarapid fuse must be used The ACx 600 protects the input and motor cables from overload when the cables are dimensioned according to the nominal current of the ACx 600 When the ultrarapid fuses of the ACx 604 are placed at the distribution board they protect the input cable in case of a short circuit ACS ACC ACP 604 6x7 Frequency Converters
33. is derated 196 for every additional 100 m 330 ft If the installation site is higher than 2000 m 6600 ft above sea level please contact your local ABB distributor or office for further information 2 See subsection Output Current Temperature Derating Fuses The input fuse ratings of the ACS ACC ACP 6x7 and recommended input fuse ratings of the ACS ACC ACP 604 are presented below A minimum rated current in amperes A s maximum 121 value V rated voltage in volts Only ultra rapid fuses guarantee proper protection for the rectifier semiconductors ACS ACC ACP 604 6x7 Frequency Converters A 5 Appendix A ACS ACC ACP 604 6x7 Technical Data Fuses ACx 604 6x7 Types Type Type DIN 43620 DIN 43653 A A s V Manufacturer Size Size Le ACx 60x 0100 3 400 105000 660 Bussmann 170M3819 1 170M3019 1 ACx 60x 0120 5 ACx 60x 0120 3 ACx 60x 0140 5 ACx 60x 0140 3 ACx 60x 0170 5 ACx 60x 0170 3 550 190000 690 Bussmann 170M5811 2 170M5011 2 ACx 60x 0210 5 ACx 60x 0210 3 700 405000 660 Bussmann 170M5813 2 170M5013 2 ACx 60x 0260 5 ACx 6xx 0400 3 ACx 6xx 0490 5 ACx 60x 0260 3 ACx 60x 0320 5 ACx 6xx 0490 3 ACx 6xx 0610 5 ACx 60x 0320 3 800 465000 660 Bussmann 170M6812 3 170M6012 3 ACx 60x 0400 5 ACx 6xx 0610 3 ACx 6xx 0760 5 ACx60x 0100 6 125 8500 660 Bussmann 170M1568 000 170M1368 000 ACx60x 0120 6 1 200
34. nom speed RL lt 700 Q A 11 11 AO2 Output current 0 4 20 mA2 a 12 Baz 12 AO2 0 motor nom current RL lt 700 Q 13 14 rH X22 o 9 15 1 DI Start olo 16 2 DI2 Stop HA 17 I 3 DIB Forward Reverse 18 4 DI4 ACCEL DECEL 1 2 19 5 Dis Constant speed select 2 20 6 DI6 Constant speed select 2 21 7 24V 24 V d c max 100 mA 22 PS 8 24V 23 9 DGND Digital Ground 24 m X23 25 boo 1 24 V Auxiliary voltage output non 26 l 2 GND isolated 24 V d c 250 mA 27 rH X25 28 1 RO11 29 2 RO12 L Relay output 1 Ready OS 30 3 RO13 X26 31 1 RO21 a aee 2 Roz2 e ay output a Running amp 33 L 3 RO23 X27 34 1 RO31 35 1 2 Ros2 Poe Relay output 3 Fault Fault 1 36 3 RO33 A 12 ACS ACC ACP 604 6x7 Frequency Converters Appendix A ACS ACC ACP 604 6x7 Technical Data NIOCP Board External control connections of ACP 600 with NIOCP board and Speed Control Application Macro are shown below For the connections of other application macros and programs see Firmware Manual
35. screw Substitution Metric to US Standard M8 5 16 inch diameter bolt M10 3 8 inch diameter bolt M12 1 2 inch diameter bolt T Tightening torque ACS ACC ACP 604 6x7 Frequency Converters A 7 Appendix A ACS ACC ACP 604 6x7 Technical Data Terminal Sizes and Tightening Torques terms used see above Input power and motor cable terminal wire size capabilities per phase and tightening torques for the ACS ACC ACP 604 6x7 are below For Mains Terminals Motor Terminals Earthing Terminals Frame ACX 600 U1 V1 W1 T U2 V2 W2 T Tale Type Earthing Cu Al Nm Cu Al BE Nm ACx 607 0100 3 0120 5 1x185 9 1x185 9 22 1x 12 185 1x 12 185 30 M12 30 R7 ACx 607 0100 6 1x120 9 1x120 9 30 1x 12 185 1x 12 185 30 M12 30 ACx 607 0120 3 0140 5 0120 6 1x185 9 1x185 9 22 1x 12 185 1x 12 185 30 M12 30 ACx 607 0140 3 0170 5 0140 6 2x 12 185 2x 12 240 44 2x 12 185 2x 12 240 44 M12 30 R8 ACx 607 0170 3 0210 5 0170 6 2x 12 185 2x 12 240 44 2x 12 185 2x 12 240 44 M12 30 ACx 607 0210 3 0260 5 0210 6 2x 12 185 2x 12 240 44 2x 12 185 2x 12 240 44 M12 30 ACx 607 00260 6 2x 12 185 2x 12 240 44 2x 12 185 2x 12 240 44 M12 30 ACx 607 0260 3 0320 5 0320 6 2x 12 185 2x 12 240 44 2x 12 185 2x 12 240 44 M12 30 R9 ACx 607 0320 3 0400 5 0400 6 2x 12 185 2x 12 240 44 2x 12 185 2x
36. supplying domestic premises This kind of use might cause radio frequency interference 1 Itis ensured that no excessive emission is propagated to neighbouring low voltage networks In some cases the natural suppression in transformers and cables is sufficient If in doubt the supply transformer with static screening between the primary and secondary windings can be used 2 The ACx 6x7 is installed according to the instructions given in this manual 3 The motor and control cables are selected as specified in this manual Note The ACx 600 must not be equipped with EMC filtering refer to Table A 1 when installed to IT networks The mains becomes connected to earth potential through the EMC filter capacitors In IT networks this may cause danger or damage the unit ACS ACC ACP 604 6x7 Frequency Converters A 29 Appendix A ACS ACC ACP 604 6x7 Technical Data Machinery Directive UL CSA Markings UL C tick Marking Compliance with AS NZS 2064 ACx 601 604 607 627 frequency converters comply with the European Union Machinery Directive 98 37 EC requirements for an equipment intended to be incorporated into machinery The UL CSA markings are often required in North America The UL UL CSA markings of the ACS 600 frequency converters are listed below x ACx 600 Type UL ULc CSA ACS 601 IP 22 x x x 480 V 500 V and 600 V ranges ACS 601 IP 54 x x x ACS 604 frame sizes R7 to R9 x x x
37. the ACx 627 It is recommended that these functions be wired to switch off the mains supply should a fuse failure or an earth fault occur Refer to the circuit diagrams Sheet 50 supplied with the unit and Chapter 3 Electrical Installation Types ACx 6x7 0400 3 0490 5 6 and up or contact your ABB representative for information ACS ACC ACP 604 6x7 Frequency Converters ACx ACS ACC ACP Xv Safety Instructions xvi ACx ACS ACC ACP ACS ACC ACP 604 6x7 Frequency Converters Table of Contents ACS 600 SingleDrive Manuals English Originals Safety Instructions OVeOrVIBW does eios ee gs gueule A queque bg dades ee CC rs iii CAUTION AA sspe ak ar a a A ERA Xa a o e RU FOR e Scu e C EO SCR NO e iii Note nocet te Mat oot ts Be d aa ma tta ide at A a a e aA ud A dS N iii Installation and Maintenance Safety 000 e eee een iv Permanent Magnet Motor 2 os RU EE RATE I eka sig ef RP d uA OR Read PRA RRA RS V Supply Gonrnecliolis siria een a een ohne e EN V Earth Ground Fault Protective Function ess xe e y ed ee ann ae vii Power Loss Hide tlirough Function esse eR lee XE boas RA TUER e vii Emergency Stop Devices au au na se wen ae os pa EC Lek RR ERE Rene RAE vii Motor Connections unseres er ie ae ee etur Nr gs viii Pulses in the Drive Output Love Rom Dee awe ee aha ROGA PATER RUE RR IR EG viii Protecting the Motor Winding os Mta eR Rte ELE p a a a viii Protecting the Motor Bearings 2 4434 tds dex FARE rp b
38. where EMC emissions must be minimized 360 high frequency earthing grounding of cable entries is done in order to suppress electromagnetic disturbances In addition cable screens have to be connected to protective earth PE in order to meet safety regulations Power cable screens are suitable for use as equipment earthing grounding conductors only when the screen conductors are adequately sized as required by safety regulations The ACx 600 earth ground terminals should not be connected in series in case of a multiple installation Incorrect earthing can cause physical injury death or equipment malfunction and increase electromagnetic interference WARNING IEC 664 requires double or reinforced insulation between live parts and the surface of accessible parts of electrical equipment which are either non conductive or conductive but not connected to the protective earth To fulfil this requirement the connection of a thermistor and other similar components to the digital inputs of ACx 600 can be implemented in three alternate ways 1 There is double or reinforced insulation between the thermistor and live parts of the motor 2 Circuits connected to all digital and analogue inputs of the ACx 600 e are protected against contact and e insulated with basic insulation the same voltage level as the converter main circuit from other low voltage circuits 3 An external thermistor relay is used The insulation of the relay m
39. 12 240 44 M12 30 ACx 6x7 0400 3 0490 5 0490 6 4x 12 185 4x 12 240 55 4x 12 185 4x 12 240 55 M10 2x2 pcs 35 2xR8 ACx 6x7 0490 3 0610 5 0610 6 4x 12 185 4x 12 240 55 4x 12 185 4x 12 240 55 M10 2x2 pcs 35 2xR9 ACx 6x7 0610 3 0760 5 0760 6 4x 12 185 4x 12 240 55 4x 12 185 4x 12 240 55 M10 2x2 pcs 35 ACx 604 0100 3 0120 5 0100 6 1x 10 120 9 1 30 1x 10 120 1 30 41 mm 29 30 R7 ACx 604 0120 3 0140 5 0120 6 1x 10 120 9 1 30 1x 10 120 1 30 41 mm 29 30 ACx 604 0140 3 0170 5 0140 6 1x 10 240 9 1x 10 240 30 3x 12 240 3x 12 240 44 M10 2 pcs 30 R8 ACx 604 0170 3 0210 5 0170 6 1x 10 240 9 1x 10 240 30 3x 12 240 3x 12 240 44 M10 2 pcs 30 ACx 604 0210 3 0260 5 0210 6 1x 10 240 1x 10 240 30 3x 12 240 3x 12 240 44 M10 2 pcs 30 ACx 604 0260 6 1x 10 240 1x 10 240 9 30 3x 12 240 3x 12 240 44 M10 2 pcs 30 ACx 604 0260 3 0320 5 0320 6 1x 10 240 9 1x 10 240 30 3x 12 240 3x 12 240 44 M10 2 pcs 30 R9 ACx 604 0320 3 0400 5 0400 6 1x 10 240 9 1x 10 240 30 3x 12 240 3x 12 240 44 M10 2 pcs 30 1 The maximum acceptable size of the cable is 3x120 70 3x AWG 0000 AWG 00 cross sectional areas of copper conductors in mm 3 x phase conductor PE conductor Aluminium cable cannot be connected due to cable lug size This is the earthing terminal
40. 15000 660 Bussmann 170M3815 1 170M1370 000 28000 170M1570 000 170M1370 000 ACx 60x 0140 6 250 28500 690 Bussmann 170M3816 1 170M3016 1 ACx 60x 0170 6 ACx 60x 0210 6 315 46500 660 Bussmann 170M3817 1 170M3017 1 ACx 60x 0260 6 400 105000 660 Bussmann 170M3819 1 170M3019 1 ACx 60x 0320 6 550 190000 690 Bussmann 170M5811 2 170M5011 2 ACx 60x 0400 6 ACx 6xx 0490 6 400 105000 660 Bussmann 170M3819 1 170M3019 1 ACx 6xx 0610 6 550 190000 690 Bussmann 170M5811 2 170M5011 2 ACx 6xx 0760 6 Note Fuses from other manufacturers can be used ifthey meet the ratings given in the table Only ultra rapid fuses guarantee proper protection for the rectifier semiconductors The fuses recommended in the table are UL R C JFRHRZ fuses 1 15000 A s and 28000 A s Bussmann fuses can be used with the ACx 60x 0120 6 A 6 ACS ACC ACP 604 6x7 Frequency Converters Example Cable Entries Terms used Appendix A ACS ACC ACP 604 6x7 Technical Data For ACS 604 0260 3 the recommended fuses for the input bridge protection are 700 A ultrarapid fuses The values Ian long and lonsg for ACS 604 0260 3 are 395 A 316 A and 480 A respectively 1 1 395 A 434 5 A and 1 5 316 A 474 A and 1 0 480A 480 A Normal fuses with nominal currents higher than 434 5 A 474 A or 480 A can be used to protect the input cable thus 450 A or 500 A fuses are selec
41. 2 ACS ACC ACP 604 6x7 Frequency Converters Chapter 3 Electrical Installation Types ACx 6x7 0400 3 A detailed view of the recommended earthing mains and motor cable 0490 5 6 and up 2 x R8 connections of the ACx 6x7 parallel connected units is presented and 2x H9 below F denotes a 360 degrees earthing Max 6 control cables E oc ie ms i B5 JOI FT 12 F E ACx 607 nos Frequency Converter U1 d wi l 2xR8and2xR9unit L I INS ro m L Line Filter 7 I EN X2 wee Pas PS i N IT NIOC NAMC Control Boards Bu zn i Line Options PE os U1 V1 ACx 604 Converter Unit ACx 604 Converter Unit 7 O e U2 v2 we U2 v2 w2 I E 1 I r du dt Filter r du dtFilter A SE r aaa os o j LU2 V2 w2 I 1 T Common Mode l j Filter i t I 1 used if the conductivity of the cable screen is lt 50 of the J conductivity of the phase conductor 2 used if the PE rail of the ACx 607 is not ea
42. 4 0100 3 0120 3 0120 5 0140 5 0100 6 0120 6 3 ACx 604 0140 3 to 0320 3 amp 0170 5 to 0400 5 0140 6 to 0400 6 gt 50 mm is needed for air cooling In addition free space is needed for terminal connections 9 louvred gratings which are visible on the dimensional drawings are not included 6 The degrees of protection is specified by listing the IEC standard IP Ingress Protection number The first digit of the IP number specifies the protection against solid objects and dirt The second digit specifies the protection against liquids IP 00 is an open chassis NEMA 1 enclosures are comparable to approximately IP 20 to IP 33 NEMA 3R enclosures are comparable to IP 32 NEMA 12 and NEMA 13 enclosures are comparable to IP 54 to IP 65 NEMA 4 enclosures are comparable to IP 65 or IP 66 First digit of IP number protection against solid objects Second digit of IP number protection against liquids O Not protected Not protected 1 Protected against solid objects larger than 50 mm 2 in dia Protected against dripping water 2 Protected against solid objects larger than 12 mm 1 2 in dia Protected against downward sprays of water up to 15 degrees from vertical 3 Protected against solid objects larger than 2 5 mm 0 1 in dia Protected against downward sprays of water up to 60 degrees from vertical 4 Protected against solid objects larger than 1 0 mm 0 04 in
43. 48 4 25 35 748 858 0170 3 0210 5 0210 6 2078 23162 830 1230 644 345 3909 81 8 91 2 32 7 48 4 25 35 749 858 0210 3 0260 5 0260 6 2078 23162 830 1230 644 345 3909 81 8 91 2 32 7 48 4 25 35 749 858 0260 3 2078 23162 830 1230 644 370 81 8 91 2 32 7 48 4 25 35 814 0320 3 20787 2316 830 1230 644 370 81 8 91 2 32 7 48 4 25 35 814 0320 5 0320 6 2078 23162 830 1230 644 375 435 81 8 91 2 32 7 48 4 25 35 825 957 0400 5 0400 6 2078 23162 830 1230 644 375 4355 81 8 91 2 32 7 48 4 25 35 825 957 0400 3 0490 5 0490 6 2078 22152 21309 644 710 87 3 87 2 83 9 25 35 1562 0490 3 0610 5 0610 6 2078 2215 9 21309 644 870 87 3 87 2 83 9 25 35 1914 0610 3 0760 5 0760 6 2078 22152 21309 644 870 87 3 87 2 83 9 25 35 1914 y Height of bottom entry exit degree of protection IP 21 1P 22 IP 42 Heights include the lifting lugs Height of top entry exit is 2132 83 9 in 2 Degree of protection IP 54 3 EMC Line Filter version 4 Weight of the IP 21 IP 22 IP 42 version 5 Weight of the 690 V unit with du dt filter 6 With cable top exit an additional 400 mm wide section A 22 ACS ACC ACP 604 6x7 Frequency Converters Appendix A ACS ACC ACP 604 6x7 Technical Data Brak
44. 50 127 191 127 191 140 110 150 ACx 604 607 0210 6 179 197 210 160 200 150 225 150 225 170 132 150 ACx 604 607 0260 6 225 248 260 200 250 179 269 179 269 210 160 200 ACx 604 607 0320 6 265 292 320 250 300 225 338 225 338 260 200 250 R9 ACx 604 607 0400 6 351 386 400 315 350 265 398 265 398 320 250 300 ACx 604 6x7 0490 6 428 470 490 400 450 340 511 340 510 400 315 350 2xR8 ACx 604 6x7 0610 6 504 555 610 500 500 428 642 428 642 490 400 450 2x R9 ACx 604 6x7 0760 6 667 734 760 630 700 504 756 504 756 610 500 500 ACS ACC ACP 604 6x7 Frequency Converters A 1 Appendix A ACS ACC ACP 604 6x7 Technical Data Pump and Fan Use Squared Load ACS 604 607 loNsq PN Frame Type Size A kw Zn phase supply voltage 380 V 400 V or ACS 604 607 0100 3 178 90 R7 ACS 604 607 0120 3 200 110 100 ACS 604 607 0140 3 260 132 R8 ACS 604 607 0170 3 300 160 ACS 604 607 0210 3 375 200 ACS 604 607 0260 3 480 250 R9 ACS 604 607 0320 3 510 1315 265 ACS 6x4 6x7 0400 3 712 400 2xR8 ACS 6x4 6x7 0490 3 912 500 2xR9 ACS 6x4 6x7 0610 3 969 560 Three phase supply voltage 380 V 400 V 415 V Bao V 460
45. 6x7 wood or plywood seaworthy package Plastic covering of the package PE LD bands PP or steel Transportation ACx 604 6x7 Upright Units without du dt filters can be transported Position also on their back in their protective package ACS ACC ACP 604 6x7 Frequency Converters A 27 Appendix A ACS ACC ACP 604 6x7 Technical Data Disposal CE Marking Compliance with the EMC Directive Industrial Low Voltage Network ACx 600 contains raw materials that should be recycled thus preserving energy and natural resources Package materials of ACx 600 units and options are environmentally compatible and recyclable All metal parts can be recycled The plastic parts can either be recycled or burned under controlled circumstances according to local regulations If recycling is not feasible all parts excluding electrolytic capacitors can be landfilled The DC capacitors of the unit contain electrolyte which is classified as hazardous waste Location of the electrolytic capacitors is shown on a sticker in the back of the front cover C11 to C13 The capacitors must be removed and handled according to local regulations For further information on environmental aspects please contact your local ABB distributor A CE mark is attached to ACx 601 607 627 frequency converters to verify that the unit follows the provisions of the European Low Voltage and EMC Directives Directive 73 23 EEC as amended by 93 68 EEC and Dir
46. 7 For installation of ACx 604 module in a cabinet refer to a supplement to this manual Converter Module Installation in User defined Cabinet EN code 61264922 The ACx 6x7 should be installed in an upright vertical position The floor that the unit is installed on should be of non flammable material as smooth as possible and strong enough to support the weight of the unit The maximum allowed deviation from the surface level must be 2 mm measured every 1 m The installation site should be levelled when needed as the ACx 6x7 is not equipped with adjustable feet The ACx 6x7 can be installed on elevated floor and over a cable duct The integrity of the supporting structure must be checked before the ACx 6x7 is placed in such a position ACx 6x7 can be installed with its back against a wall Sufficient room around the ACx 6x7 is required to enable cooling air flow service and maintenance The wall behind the unit should be of non flammable material Fastening the cabinet to the floor is especially important in installations subjected to vibration or other movement Fasten the cabinet to the floor with bolts through the holes at its base or from outside with fastening clamps attached to its bottom front and back edges if not installed against wall Check the intended installation site for sufficient room Check that there is nothing on the floor to inhibit installation See the dimensional drawings in ACS ACC ACP 607 627 Dimension
47. ACS 600 Hardware Manual en ACS ACC ACP 604 607 627 Installation Frequency Converters Technical Data il 75 to 700 HP AA EP ED P EP Up ACS 600 SingleDr ive Manuals English Originals GENERAL MANUALS appropriate hardware manual is included in the delivery ACS ACC ACP 601 Hardware Manual EN 61201360 2 2 to 110 kW Safety instructions Cable selection Mechanical and electrical installation Maintenance Technical data Dimensional drawings ACS ACC 611 Supplement EN 61504443 included in ACx 611 deliveries only Safety instructions Installation Maintenance Fault tracing Parameters Technical data Dimensional drawings ACS ACC ACP 604 607 627 Hardware Manual EN 61201394 55 to 630 kW Safety instructions Cable selection Mechanical and electrical installation Maintenance Technical data ACS ACC ACP 607 627 Dimensional Drawings 64484311 55 to 630 kW Dimensional drawings Cable routing ACS ACC 607 617 627 677 Hardware Manual EN 61329005 75 to 3000 kW Safety instructions Cable selection Mechanical and electrical installation Drive section commissioning Maintenance Technical data ACS ACC 607 617 627 677 Dimensional Drawings EN 64488422 75 to 3000 kW Dimensional drawings Converter Module Installation in User defined Cabinet EN 61264922 included in modules deliveries only Safety instructions Cabinet design Wiring
48. Board ACP 600 NIOCP 01 Board Analogue Inputs The advantage of the differential analogue input is that the earth potential of the device or transmitter sending an analogue signal can differ up to 15 V from the earth potential of the ACx 600 chassis without disturbing the signal Differential input also efficiently attenuates common mode disturbances coupled to control cables ACS 600 Two Programmable Differential Current Inputs 0 4 to 20 mA Hj 100 Q ACC 600 Two Differential Current Inputs 0 to 20 mA Rin 100 O ACP 600 One Programmable Differential Current Input 0 to 20 mA Hj 100 Q ACS ACP 600 One Programmable Differential Voltage Input ACS 600 0 2 to 10 V Rin gt 200 KQ ACP 600 0 to 10 V Rip gt 200 kQ ACC 600 One Differential Voltage Input 0 to 10 V Rin gt 200 kQ Common Mode Voltage 15 VDC max Common Mode Rejection Ratio gt 60 dB at 50 Hz Resolution 0 1 10 bit Inaccuracy 0 5 Full Scale Range at 25 C Temperature Coefficient 100 ppm C max Input Updating Time Application Program Updating Time Standard 5 x 12 ms Standard 6 x Al1 12 ms AI2 and AI3 6 ms Crane 44 ms Motion Control 1ms 12 ms with NAIO extension module Two Bipolar Differential Voltage Inputs t 10 V Rin 30 KQ Common Mode Voltage 20 VDC max Common Mode Rejection Ratio 60 dB at 50 Hz Resolution 0 02 12 bit Accu
49. Fault tracing Fieldbus control PFC application example System EN 63700177 Commissioning of the System Application Program Control Panel use Software description Parameters of the System Application Program Fault tracing Terms Application Program Template EN 63700185 Commissioning of the Drive Section Control Panel use Software description Parameters Fault tracing Terms OPTION MANUALS delivered with optional equipment Fieldbus Adapters I O Extension Modules Braking Choppers etc Installation Programming Fault tracing Technical data ACS ACC ACP 604 607 627 Frequency Converters 55 to 630 kW 75 to 700 HP Hardware Manual This manual concerns the ACS 607 ACS 627 ACC 607 ACC 627 ACP 607 and ACP 627 frequency converters and the ACS 604 ACC 604 and ACP 604 frequency converter modules In the text they are collectively referred to as ACx 604 6x7 or ACx 600 3AFY 61201394 R0525 REV D EN EFFECTIVE 15 6 2001 SUPERSEDES 9 1 2001 2001 ABB Industry Oy All Rights Reserved Safety Instructions Overview This chapter states the safety instructions that must be followed when installing operating and servicing the ACS ACC ACP 604 607 627 If neglected physical injury and death may follow or damage may occur to the frequency converter the motor and driven equipment The material in this chapter must be studied before attempting any work on or with the unit The following no
50. ION Checks aurca eor res e aC B C ca a wa TR Re ra Co uote e 3 1 Mains FUS8S cio Dun ae Stee a wad Pads p ang ERR eA ann ah Pad DR TE Biene 3 1 Input Cable Protection zu sob ae eua os Da i eden cra cos doter dos ert bre 3 2 sea Cs nenn Ker xta quae 3 2 Power Gables taa Tr cp PI 3 2 Alternative Power Cable Types 2 ue Ex ee x eR 3 3 Motor Cable Sl ug ae 3 Yt Ute aide o nee ett o Ue we e fn dee ee aaah Se Gad Sle radeon 3 3 Special for Types ACx 6x7 0400 3 0490 5 and 0490 6 and up 2 000 0 eae 3 4 Control Ga3blB8 oos ith pend da io Pro 3 d Geo teet lcs NE AA AA PCR dio 3 6 Gable Routing TM TC P lero o eee A E EEE RAEES 3 7 Mains Motor and Control Cable Connection llle RR 3 8 Frame Sizes R7 TO ROS asser le Eos dex oig d OR Y a ac DURER EROS dea on a 3 9 Types ACx 6x7 0400 3 0490 5 6 and up 2x R8 and 2 x R9 0 2 eee eee 3 13 Control Cable Connecting Procedure 0 0 eres 3 15 Pulse Encoder Insulation ACP 600 Si ioc se Sn o Svp Pn Rx RS MER Un 3 19 Pulse Encoder Phasing ACP 600 NIOCP Board 0 00 cece tee 3 19 Installation of Optional Modules and DriveWindow 0 000 cece eens 3 20 Installation of Other Optional Equipment 0 00 eee 3 23 Chapter 4 Installation Checklist Installation Checklist Des A a Recte ao Re ecu o Ewa I aeta Hed 4 1 Chapter 5 Maintenance Healtsille 26d A Rd Edu D LU ICE dr 5 1 l CT 5 1 CAPACES vocor eq emere Kos qub
51. L 1 2 7 Ar A MEC T la 5 DI5 Constant speed select 5 GND 18 6 DI6 Constant speed select 2 6 24V 19 j 7 24V 24 V d c max 100 mA 20 8 24V Connector X29 for RS 485 connection al p 9 DGND Digital Ground X23 1 TRANS 2 FAULT 22 1 24 V Auxiliary voltage output non 3 g Standard Modbus Link 23 2 GND_ isolated 24 V d c 250 mA 2 X25 E Ae 24 e 1 Rot 2s 5 GND Dam 2 ro 2 M ea 6 24V X 26 3 RO13 Connector shield is connected via RC filter to frame X26 27 I 1 RO21 a Dem 2 RO22 c ay output Running Q 29 3 RO 3 X27 amp 30 1 RO31 En wv P LL elay outpu Fault 31 2 RO32 Fault 1 3 3 RO33 ACS ACC ACP 604 6x7 Frequency Converters A 11 Appendix A ACS ACC ACP 604 6x7 Technical Data Optional Terminal Block 2TB US Version External connections to optional terminal block 2TB This option is available only with ACS 600 Standard Application Program US version External control connections with Factory Macro are shown below For the connections of other application macros and programs see Firmware Manual Terminal Block Size X21 X22 cables 0 5 to 1 5 mm 20 to 16 AWG 2TB X23 X25 X26 X27 cables 0 5 to 2 5 mm 20 to 14 AWG Control Cable Lead through Size Q 2 x 3x2 11 mm 0 08 to 0 43 Factory settings of application software selection B type code
52. Noise Levels Frequency Converter Heat Loss Noise Type kW dB A ACx 604 607 0100 3 1 9 65 8 ACx 604 607 0120 3 2 8 65 8 ACx 604 607 0140 3 2 8 61 8 ACx 604 607 0170 3 3 3 61 8 ACx 604 607 0210 3 4 0 61 8 ACx 604 607 0260 3 5 0 67 6 ACx 604 607 0320 3 6 3 67 6 ACx 6x4 6x7 0400 3 79 65 ACx 6x4 6x7 0490 3 10 0 71 ACx 6x4 6x7 0610 3 12 5 71 ACx 604 607 0120 5 2 3 65 8 ACx 604 607 0140 5 2 8 65 8 ACx 604 607 0170 5 3 3 61 8 ACx 604 607 0210 5 4 0 61 8 ACx 604 607 0260 5 5 0 61 8 ACx 604 607 0320 5 6 3 67 6 ACx 604 607 0400 5 79 67 6 ACx 6x4 6x7 0490 5 10 0 65 ACx 6x4 6x7 0610 5 12 5 71 ACx 6x4 6x7 0760 5 15 8 71 ACx 604 607 0100 6 1 9 65 8 ACx 604 607 0120 6 2 3 65 8 ACx 604 607 0140 6 2 8 61 8 ACx 604 607 0170 6 3 3 61 8 ACx 604 607 0210 6 4 0 61 8 ACx 604 607 0260 6 5 0 61 8 ACx 604 607 0320 6 6 3 67 6 ACx 604 607 0400 6 79 67 6 ACx 6x4 6x7 0490 6 10 0 65 0 ACx 6x4 6x7 0610 6 12 5 71 0 ACx 6x4 6x7 0760 6 15 8 71 0 A 20 ACS ACC ACP 604 6x7 Frequency Converters Dimensions and Appendix A ACS ACC ACP 604 6x7 Technical Data Dimensions and weights of the ACx 604s are given below Weights ACx 604 pur Height Width Depth Weight eig i ep eig ACS 604 Typs mm in mm in mm in kg Ibs U m 0100 3 0120 5 0100 6 860 33 86 480 18 89 428 16 85 88 194 0120 3 0140 5 0120 6 860 33 86 480 18 89 428 16 85 88 194
53. RING Sa ct a A aan tecti e A MM a c Es A 30 Ul ii thick keh tet ed reet oet dte x theta dba ets Patras ud rds asset fines A 30 ROUGE Marking os dns scare soa ettet o RECS ne OO RA UR dog er nos gh las SR SUE ened at Tu d A 30 Compliance with AS NZS 2064 2 bed eee Vee aw He AENEA A 30 Equipment Warranty and Liability nr Sek rn tee EX WR RR RR s A 31 Limitation of Liability ausser la ee Di Bk MwA Rb dex ed A 32 ACS ACC ACP 604 6x7 Hardware Manual Xix XX ACS ACC ACP 604 6x7 Hardware Manual Chapter 1 Introduction General The ACS 600 product family of three phase frequency converters and converter modules for speed control of squirrel cage electric motors includes the ACS 600 for most applications the ACP 600 for positioning synchronising and other high precision control applications the ACC 600 for crane drive applications the ACS 600 MultiDrive for multidrive applications The application programs are introduced in Appendix A Study this manual carefully before storaging installing commissioning operating or servicing the frequency converter We expect that you have a basic knowledge of physical and electrical fundamentals electrical wiring practices electrical components and electrical schematic symbols Other Manuals Items concerning the ACx 6x4 6x7 in other manuals are listed below For EN codes of the manuals refer to inside of the front cover of this manual For
54. able Encoder Cable ACP 600 All control cables must be shielded As a general rule the control signal cable shield should be earthed directly in the ACx 600 The other end of the shield should be left unconnected or earthed indirectly via some nanofarad high frequency high voltage capacitor e g 3 3 nF 3000 V The screen can also be earthed directly at both ends if they are in the same earth line with no significant voltage drop between the end points Twisting the signal wire with its return wire reduces disturbances caused by inductive coupling Pairs should be twisted as close to terminals as possible A double shielded twisted pair cable figure a e g JAMAK by NK Cables Finland must be used for analogue signals and is recommended for the pulse encoder signals Employ one individually shielded pair for each signal Do not use common return for different analogue signals A double shielded cable is the best alternative for low voltage digital signals but single shielded twisted multipair cable figure b is also usable 4 m a b A double shielded twisted A single shielded twisted pair cable multipair cable The analogue and digital signals should be run in separate screened 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
55. al Drawings Make cable duct opening if cables come from a cable duct Smooth cable duct edges if required ACS ACC ACP 6x7 Frequency Converters 2 1 Chapter 2 Mechanical Installation Fastening Clamps Insert the clamp into the longitudinal hole in the edge of the cabinet frame body and fasten it with a bolt to the floor The longitudinal holes for fixing are marked in the dimensional drawings Cabinet frame body 65 La Cabinet frame body 4 10 Dimensions of the fastening clamp Holes inside the Cabinet 1 See ACS ACC ACP 607 627 Dimensional Drawings for the fastening hole locations 2 Make holes for bolts to the floor Insert plugs into the fastening holes 3 Place the frequency converter carefully onto the holes 4 Place bolts in the plugs 5 Tighten the bolts 2 2 ACS ACC ACP 6x7 Frequency Converters A Insulation Checks PE Mains Fuses A Chapter 3 Electrical Installation WARNING The electrical installation described in this chapter should only be carried out by a qualified electrician The Safety Instructions on the first pages of this manual must be followed Negligence of these instructions can cause injury or death Every ACx 600 unit has been tested for insulation between main circuit and chassis 2500 V rms 50 Hz for 1 second at the factory Therefore there is no need to check the insulation on the unit again When checking the
56. ble is recommended To operate as a protective conductor the shield conductivity must be at least 50 of the conductivity of the phase lead Compared to a four conductor system the use of symmetrical shielded cable reduces electromagnetic emission of the whole drive system as well as motor bearing currents and wear The motor cable and its PE pigtail twisted screen should be kept as short as possible in order to reduce electromagnetic emission as well as capacitive current 3 2 ACS ACC ACP 604 6x7 Frequency Converters Alternative Power Cable Types below Recommended Symmetrical shielded cable three phase conductors and a concentric or otherwise symmetrically constructed PE conductor and a shield PE conductor hield and shield PE Chapter 3 Electrical Installation Power cable types that can be used with the ACx 600 are represented A separate PE conductor is required if the conductivity of the cable shield is 50 of the conductivity of the phase conductor Shield PE A four conductor system three phase conductors and a protective conductor Not allowed for motor cables PE _ Shield Motor Cable Shield To effectively supress radiated and conducted radio frequency emissions the shield conductivity must be at least 1 10 of the phase conductor conductivity One way of evaluating the effectiveness of the shield is the shield inductance which must be low and only slightly depe
57. bndmax Phd Size 4 5min 1 5min 4 5min 1 5min 13 15s 2 15s A A HP A A A A HP Three phase supply voltage 380 V 400 V 415 V 440 V 460 V 480 V or 500 V ACS 604 607 0120 4 156 172 125 113 168 113 224 75 R7 ACS 604 607 0140 4 180 198 150 141 208 141 270 100 ACS 604 607 0170 4 216 238 150 172 246 172 328 125 R8 ACS 604 607 0210 4 260 286 200 200 300 200 400 150 ACS 604 607 0260 4 316 348 250 240 360 240 480 200 ACS 604 607 0320 4 414 455 300 350 300 450 300 600 250 R9 ACS 604 607 0400 4 480 528 400 365 548 365 730 300 Note The US manufactured units are labelled to 4 types The information in this manual concerning the corresponding 5 type applies to them The output current is calculated by multiplying the current given in the Temperature Derating rating table by the derating factor Temperature derating factor for ACx 6x7 General rule Above 40 C 104 F 35 C 95 F for types ACS 60x 0120 03 and ACS 60x 0140 5 with Jonigq rating the rated output current is decreased by 1 5 for every additional 1 C 1 8 F up to 50 C 122 F This applies to loy and lewsq for long no derating is needed Example 1 f the ambient temperature is 50 C 122 F the derating factor is 100 i5 10 C 85 or 0 85 The output current is
58. cation Macros Various application programs are available for the ACS 600 frequency converters Not all selections are available for all types One application program at a time can be loaded in the memory of the frequency converter ACS 600 Application Programs Standard Decanter Centrifuge Pump and Fan Control PFC Master Follower M F Extruder Centrifuge Spinning Control Motion Control Crane System The macros of the application programs are introduced below p eun Macros For Standard Factory basic industrial applications Hand Auto applications that require frequent switching between two external control locations PID Control closed loop processes Torque Control processes that require torque control Sequential Control operation at preset constant speeds User macro 1 amp 2 user s own customised parameter settings Pump and Pump and Fan Control pump or fan station control Fan Control Hang Auto applications that require frequent switching between two external control locations and or speed control of a pump or a fan Master Master Follower drives which are coupled to each other Follower macros included in Standard Application program Spinning Spinning control running motor rotating bobbins in ring frame Control machines Motion Conrol Torque Control processes that require torque control Speed Control closed loop speed control
59. d With Standard Application Program check the settings of Parameters 21 03 STOP FUNCTION and 16 01 RUN ENABLE For program version 6 x check also Parameter 21 07 RUN ENABLE FUNC For further information see the Firmware Manual In scalar control the contactor can be opened with ACS ACC 600 running Varistors or RC networks AC or diodes DC should be used to protect against voltage transients generated by contactor coils The protective components should be mounted as close as possible to the contactor coils Protective components should not be installed at the NIOC board terminal block Relay Contacts When used with inductive loads relays contactors motors the relay contacts of ACx 600 must be protected with varistors or RC networks AC or diodes DC against voltage transients The protective components should not be installed at the NIOC board terminal block Earth Ground The ACx 600 and adjoining equipment must be properly earthed Connections The ACx 600 and the motor must be earthed at the installation site to ensure personnel safety in all circumstances and in addition to reduce electromagnetic emission and pick up Make sure that earthing grounding conductors are adequately sized as required by safety regulations Xii ACx ACS ACC ACP ACS ACC ACP 604 6x7 Frequency Converters Components Connected to Digital Analogue Inputs A Safety Instructions In CE compliant installations and in other installations
60. e two parts of the ead through plate by tightening the positioning screws ACS ACC ACP 604 6x7 Frequency Converters 3 17 Chapter 3 Electrical Installation 6 Top entry If more than one cable go through a grommet the grommet must be sealed by Loctite 5221 catalogue number 25551 Side view Apply Loctite 5221 inside the grommet i Attach control LAA S cables to the supporting plate Connect the earthing wire to the PE busbar 7 Connect the control cables in appropriate terminal to NIOC NIOCP board or optional terminal block X2 2TB or other options on the DIN rail Refer to Appendix A and Firmware Manual Tighten Screw to secure connection Connect the twisted screen as short as possible to the earthing rail E of the terminal 8 Close the cabinet door if no other cables are to be connected 3 18 ACS ACC ACP 604 6x7 Frequency Converters Chapter 3 Electrical Installation Control Panel in Connect the Control Panel cable to terminal X19 of the NAMC 1 1 51 Remote Use or with the NAMC 03 board to terminal X28 of the NIOC board X300 of the NIOCP board with NAMC 03 ACx 601 604 with NAMC 11 51 board Panel cable with screened connectors metal enclosure NIOC NAMC 11 51 with NDCO X28 T NAMC 11 51 X19 T N X19 Earth the cable Screen at the near earthing screw FI NAMC 11 51 x300 oo NIOCP board Pulse Encoder The pulse encoder shall be
61. ective 89 336 EEC as amended by 93 68 EEC EMC stands for Electromagnetic Compatibility It is the ability of electrical electronic equipment to operate without problems within an electromagnetic environment Likewise the equipment must not disturb or interfere with any other product or system within its locality The EMC Directive defines the requirements for immunity and emissions of electrical equipment used in the European Economic Area The EMC product standard EN 61800 3 covers the requirements stated for frequency converters The ACx 607 627 frequency converters 55 kW to 630 kW comply with the EMC Directive in industrial low voltage network public low voltage network restricted distribution and IT networks unearthed mains 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 transformers and cables is sufficient If in doubt the ACx 600 can be equipped with EMC filtering refer to Table A 1 or the supply transformer with static screening between the primary and secondary windings can be used 2 The ACx 6x7 is installed according to the instructions given in this manual 3 The motor and control cables are selected as specified in this manual Note It is recommended to equip the ACx 600 with the EMC filtering if there is equipment sensitive to conducted emission connected to the same supply transformer as the
62. ench Spanish Torque Control Sequential Control Portuguese Pump and Fan Control F PFC Pump and Fan Control English UK amp Am German Italian Dutch G Pump and Fan Control Hand Auto English UK amp Am Danish Swedish Finnish H Pump and Fan Control Hand Auto English UK amp Am French Spanish Portuguese Master Follower J Master Follower Macros included in English UK amp Am German Italian Dutch selection C K Master Follower Macros included in English UK amp Am Danish Swedish selection D Finnish L Master Follower Macros included in English UK amp Am French Spanish selection E Portuguese M Master Follower Macros included in English UK amp Am French Spanish selection B Portuguese System N System application English German ACS 600 MultiDrive Motion Control P ACP 600 Torque Control Speed Control Positioning Synchronising English German Q ACP 600 Torque Control Speed Control English German Crane S Crane Master Follower Control English Spinning Control V Spinning control English Custom T Application program template English FCB Programmable Y Special application program Custom specified Decanter Centrifuge P Decanter English German Extruder Q Extruder Hand Auto PID Control English German Torque Control Sequential Control User macro 1 amp 2 Centrifuge 2 Centrifuge English Traverse Control
63. ent e e Short circuit e ee External fault e oe e e Motortorque 2 2 DC overvoltage e e e e Motor e ee e e Motor speed o e overtemperature Supply phase e ee oe Thermistor Pt 100 e e Reference 1 e DC undervoltage e Motor stalled e e e Reference 2 e Overfrequency e e e Motor underload e e e Actual value 1 e Loss of Control Panel e Loss of motor phase Position error e Internal fault o e e e Earth fault e e e e Synchron e error Internal fault on the e e e e Speed measurement o Position 4 I O control board threshold Ambient temperature e e e e Motor overspeed e Joystick e User Macro e eo e Torque e Brake long e falling time Braking chopper in e Torque proving e fieldbus mode Inverter overload e Master Follower e e communication No motor data eo e Brake e ID Run fail e e e Communication test o Motor fan control and e Following error o diagnostics Position limits ojojej o Communication error Encoder interface ojojejo module Overspeed o Preprogrammed Warnings ACS 600 temperature Motor Identification Run Drive Identification Number change User Macro Target position ACP Programmable Automatic Reset Functions ACS 600 Standard Application Program only after overcurrent overvoltage undervoltage and analogue input below minimum value Information Functions ACx 600 control firmware package version ACx 600 application program
64. equired Encoder Type the type listed here or equivalent GI 356 IRION amp VOSSELER ROD 426A Heidenhain Encoder Signals Signal level Load capacity 5 V rectangular pulse signals Time between edges a gt 0 8 us at fmax Edge steepness t lt 120 ns Delay of reference signal Z zero pulse tg 60 ns Sampling frequency fmax 200 kHz ACS ACC ACP 604 6x7 Frequency Converters Appendix A ACS ACC ACP 604 6x7 Technical Data Encoder Signals A characteristic of encoder signals in applications using the incremental encoder for forward direction is presented below 5V Z aaa da ACS ACC ACP 604 6x7 Frequency Converters Appendix A ACS ACC ACP 604 6x7 Technical Data Enclosures Space The cabinets degrees of protection and free space requirements of Requirements ACx 600 types are given below ACx 600 Type Enclosure Degree of Space above Space below Space on Space in Protection left right front back 5 mm in mm in mm in mm in 601 wall mounted metal frame IP 22 IP 541 300 12 300 12 50 50 2 2 20 0 0 8 0 6042 frame R7 IP 22 300 12 300 12 50 50 2 2 20 0 0 8 0 6049 frames R8 and R9 IP 00 400 16 0 o 50 50 2 2 100 0 4 0 IP 219 22 200 8 0 0 0 0 200 0 8 0 6x7 Common cabinet IP 42 54 1 not for R7 frame size ACx 601 0100 3 0120 3 0120 5 0140 5 0100 6 0120 6 not for ACP 601 units ACx 60
65. for the PE bus and the frame of the ACx 604 module The terminal is to be connected to the PE bus of the cabinet the module is installed in 3 Cable size 6 AWG 300 MCM Isolated Stud terminal A 8 ACS ACC ACP 604 6x7 Frequency Converters Appendix A ACS ACC ACP 604 6x7 Technical Data External Control External control connections of ACS 600 equipped with Standard Connection Diagrams Application Program Factory Macro are shown below External control connections are different with other application macros and programs see Firmware Manual External control wiring is connected either directly to terminals on the NIOC board or through an optional terminal block If an optional I O terminal block is furnished the control panel code 16th digit of the ACS 600 type code is 4 or 5 Refer to Chapter 1 Introduction for the ACS 600 type code description An optional terminal block can be designated X2 IEC standard designation or 2TB ANSI standard designation for US manufactured units only The 2TB arrangement is supplied in drives with 8 as the 20th digit of the ACS 600 type code When making the external control connections compare carefully the terminal configuration found in the drive with diagrams below to ensure that the correct diagram is used External control wiring of ACP 600 is connected either to terminals on the NIOC board or the NIOCP board External control connections to NIOCP board are shown below
66. he ACx 6x7 centre of gravity is quite high and there is the risk of overturning The ACx 6x7 can be laid on its back to fit through confined spaces Exercise appropriate care when manoeuvring the unit to avoid damage and injury This work should only be attempted with two or more people working together CAUTION Make sure that dust from drilling does not enter the ACx 600 when installing Electrically conductive dust inside the unit may cause damage or lead to malfunction CAUTION The ACx 6x7 should not be fastened by any other point than the holes at its base or the fastening hooks Do not fasten the ACx 600 by riveting or welding Xiv ACx ACS ACC ACP ACS ACC ACP 604 6x7 Frequency Converters Special for ACx 6x7 Units from 315 to 630 kW A Note Safety Instructions For types ACx 6x7 0400 3 and 0490 5 6 and up note the following issues WARNING Make sure that the ACx 6x7 is disconnected from the mains network during installation The switch fuse with handle in the front door of the ACx 6x7 does not switch off power from the EMC Line Filter Disconnect the ACx 6x7 with EMC Line Filter from the mains network at the distribution board Wait for 5 minutes before working on the frequency converter the motor or the motor cable On units not equipped with main contactors additional wiring by the commissioner is required for activation of the mains fuse supervision of the ACx 6x7 and the earth fault detection functions of
67. he grommet and the EMI conductive cushions If you have several cables bunch them together at the grommet but ensure that each cable has a proper contact to the cushions on both sides Strip off the cable plastic sheath above the base plate only a distance wide enough to ensure proper connection of the bare screen and the EMI conductive cushions Earth the screen between the EMI conductive cushions a If the outer surface of the screen is conductive Push the two parts of the ead through plate together so that the EMI conductive cushions press tightly round the bare Screen 3 16 ACS ACC ACP 604 6x7 Frequency Converters Chapter 3 Electrical Installation b If the outer surface of the screen is covered with non conductive material Stripped cable Conductive surface of Stripped part covered the screen exposed with copper foil Copper foil I L ae OPTED t Screened twisted pair Cable screen Earthing wire Cutthe screen at the midpoint of the bare part Be careful not to cut the conductors Turn the screen inside out to expose its conductive surface Cover the turned screen and the stripped cable with copper foil to keep the shielding continuous Note The earthing wire if present must not be cut Push the two parts of the lead through plate together such that the EMI conductive cushions press tightly round the foil covered screen 5 Lock th
68. indow PC tool and ACx 600 optional modules such as fieldbus adapters I O extension modules and the pulse encoder interface Connection examples are given at the end of the section The module should be installed on the DIN mounting rail inside the cabinet Follow the instructions given in the Mechanical Installation chapter of the module manual The 24 V d c supply for one optional module is provided by the NIOC NIOCP board of the converter NIOC terminal X23 NIOCP terminal X4 The location of the NIOC NIOCP board is shown in the dimensional drawings Appendix B Optional modules are connected via a DDCS fibre optic link to the NAMC board or NDCO board both mounted on top of the NIOC board The terminals on the NAMC NDCO board to which the cables are connected are given in the table below Channel CH1 is on the NAMC 11 51 board Channels CHO CH2 and CH3 are on the NDCO board NAMC 3 board includes channels CHO to CH3 Module Type Channel Terminals Fieldbus Adapter Modules CHO V13 V14 I O Extension Modules CH1 V15 V16 Pulse Encoder Interface Module CH2 with ACS 600 V17 V18 Standard Application Program 5 x 6 x CH1 with ACS 600 System V15 V16 Crane Master Follower and Template Application Program Double Pulse Encoder Interface CH2 V17 V18 Module for ACP 600 only Drive Window CH3 V19 V20 on NDCO board when NAMC 1 1 51 board is used 1 Drive Window Light is co
69. ing Chopper The widths of units with braking chopper are below Dimensions Width with Width with Width with Width with Width with Width with Braking Braking Braking Braking Braking Braking ACx 6x7 Chopper Chopper and ACx 6x7 Chopper Chopper and ACx 6x7 Chopper Chopper and Type Resistor s Type Resistor s Type Resistor s mm in mm in mm in mm in mm in mm in 0100 3 830 32 7 1230 48 4 0120 5 830 32 7 1230 48 4 0100 6 830 32 7 1230 48 4 0120 3 830 32 7 1230 48 4 0140 5 830 32 7 1230 48 4 0120 6 830 32 7 1230 48 4 0140 3 1230 48 4 1230 48 4 I 0170 5 1230 48 4 1230 48 4 0140 6 1230 48 4 1230 48 4 0170 3 1230 48 4 1530 60 2 I 0210 5 1230 48 4 1230 48 4 0170 6 1230 48 4 1230 48 4 0210 3 1230 48 4 1530 60 2 0260 5 1230 48 4 1530 60 2 0210 6 1230 48 4 1230 48 4 0260 3 1230 48 4 1530 60 2 0320 5 1230 48 4 1530 60 2 0260 6 1230 48 4 1530 60 2 0320 3 1230 48 4 1530 60 2 0400 5 1230 48 4 1530 60 2 0320 6 1230 48 4 1530 60 2 0400 3 2930 115 4 3530 139 0490 5 2930 115 4 3530 139 0400 6 1230 48 4 1530 60 2 0490 3 2930 115 4 3530 139 0610 5 2930 115 4 3530 139 0490 6 2930 115 4 3530 139 0610 3 2930 115 4 3530 139 0760 5 2930 115 4 3530 139 0610 6 2930 115 4 3530 139 0760 6 2930 115 4 3530 139 ACS ACC ACP 604 6x7 Frequency Converters A 23 Appendix A ACS ACC ACP 604 6x7 Technical Data Application Programs Appli
70. insulated electrically from the stator or the Insulation ACP 600 rotor to prevent forming of a current path through the pulse encoder The usual coupling type encoder must have an electrically insulating coupling When a hollow shaft type pulse encoder is used the insulation can be implemented by insulating the ball joints of the engaging arm or insulating the bar of the engaging arm Shield of the encoder cable should be insulated from the encoder frame Pulse Encoder When the encoder is connected correctly running the drive in the Phasing ACP 600 Forward positive direction should produce positive encoder feedback NIOCP Board On incremental encoders the two output channels usually marked 1 and 2 or A and B are 90 electrical apart from each other When rotated clockwise most encoders but not all have channel 1 leading channel 2 Determine the leading channel by referring to the encoder documentation or by measuring with an oscilloscope The encoder output channel that leads when the drive runs Forward should be connected to NIOCP input A the output channel that trails to NIOCP input B The zero reference output channel is connected to NIOCP input Z ACS ACC ACP 604 6x7 Frequency Converters 3 19 Chapter 3 Electrical Installation Installation of Optional Modules and DriveWindow Placement Power Supply for the Module Fibre Optic Link This section gives general installation instructions for Drive W
71. irflow direction must be from bottom to top Also use a vacuum cleaner at the air outlet to trap the dust Fan rotation must be prevented in order to prevent bearing wear Fan The cooling fan lifespan is about 60 000 hours R7 or 30 000 hours R8 and R9 The actual lifespan depends on the frequency converter usage and ambient temperature Fan failure is often preceded by increasing noise from fan bearings and gradual rise of the heatsink temperature in spite of heatsink cleaning If the frequency converter is operated in a critical part of a process fan replacement is recommended once these symptoms start appearing Capacitors The ACx 600 intermediate circuit employs several electrolytic capacitors Their lifespan is about 100 000 hours It depends on the frequency converter loading and the ambient temperature Capacitor life can be prolonged by lowering the ambient temperature It is not possible to predict capacitor failure Capacitor failure is usually followed by a mains fuse failure or a Fault trip Contact ABB if capacitor failure is suspected Replacements are available from ABB Do not attempt operation with other than ABB specified spare parts Reforming Converter DC link capacitors need to be reformed re aged if the converter has been non operational for more than one year Without reforming capacitors may be damaged when the converter starts to operate The reforming methods introduced here require that the converter has
72. l as the mains fuse supervision function On each converter unit remove the front cover plate and verify that the transformer is set to the correct supply voltage 2 Both the left hand and right hand cabinets include an auxiliary voltage transformer designated T21 and T10 respectively pointed out in Appendix C Verify that these transformers are set to the correct supply voltage The mains fuse supervision function uses the outputs of transformers T21 LH cabinet T10 RH cabinet and T41 inside each converter unit for detecting mains fuse failure The fuse condition information is wired to terminal block X3 and further to the main contactors if present The internal earth fault protective function is not in use in 12 pulse supplied ACx 627 units Earth fault detection is implemented by means of a separate unit wired to terminal block X3 and further to the main contactors if present On units not equipped with main contactors additional wiring by the commissioner is required for activation of the mains fuse supervision and ACx 627 earth fault detection functions It is recommended that these functions be wired to switch off the mains supply should a fuse failure or an earth fault occur Refer to the circuit diagrams Sheet 50 supplied with the unit 3 14 ACS ACC ACP 604 6x7 Frequency Converters Chapter 3 Electrical Installation Control Cable To connect the control cables for the ACx 6x7 carry out the follo
73. magnetic Compatibililty Standard 1998 Radiocommunications Compliance Labelling Incidental Emissions Notice 1998 AS NZS 2064 1997 Limits and methods of measurement of electronic disturbance characteristics of industrial scientific and medical ISM radiofrequency equipment Radiocommunication Regulations of New Zealand 1993 The above rules define the essential requirements for emissions of electrical equipment used in Australia and New Zealand The standard AS NZS 2064 Limits and methods of measurement of electronic disturbance characteristics of industrial scientific and medical radiofrequency equipment 1997 covers the detailed requirements for three phase frequency converters A 30 ACS ACC ACP 604 6x7 Frequency Converters Equipment Warranty and Liability Appendix A ACS ACC ACP 604 6x7 Technical Data The ACx 607 frequency converters comply with AS NZS 2064 for class A equipment suitable for use in all establishments other than domestic and those directly connected to a low voltage network which supplies buildings used for domestic purposes The compliance is valid with the following provisions 1 The ACx 600 is equipped with EMC filtering refer to Table A 1 2 The ACx 607 is installed according to the instructions given in this manual 3 The motor and control cables are selected as specified in this manual 4 Maximum cable length is 100 metres Note The ACx 600 must not be equipped with EMC filte
74. mix 24 VDC and 115 230 VAC signals in the same cable The cable type with braided metallic screen e g OLFLEX LAPPKABEL Germany has been tested and approved by ABB Industry Min 4 0 25 mm 2 0 5 mm min single shielded twisted multipair cable optical coverage gt 91 The maximum cable length is 150 m Suitable cable is available from ABB 3 6 ACS ACC ACP 604 6x7 Frequency Converters Control Panel Cable Cable Routing Chapter 3 Electrical Installation In remote use the cable connecting the Control Panel to the ACx 600 must not exceed 3 metres The cable type tested and approved by ABB Industry is used in Control Panel option kits The motor cable should be installed away from other cable routes Motor cables of several frequency converters can be run in parallel installed next to each other It is recommended that the motor cable mains cable and control cables be installed on separate trays minimum distance 500 mm Long parallel runs of motor cable with other cables should be avoided in order to decrease electromagnetic interference caused by the rapid changes in the frequency converter output voltage Where control cables must cross power cables make sure they are arranged at an angle as near to 90 degrees as possible Extra cables should not be run through the ACx 600 The cable trays shall have good electrical bonding to each other and to the earthing eletrodes Aluminium tray systems can be used t
75. n RAS RE op E ok EE ae ower deg viii Requirements Tables e ica tan s ea eU EORR EE IONS EET viii Power Factor Compensation Capacitors 2 000 cece eee xii Output Contactors raes used Pide ie te A UNDA LA oM rr De da O Bones E frs xii Relay Contacts POT I c rrr xii Earth Ground Connections ote Prices b ee Sette FREE xii Components Connected to Digital Analogue Inputs liliis xiii EM ie aat ioa A IA RETE TR o re Ca A Ga ee ae a c Me wate meee re een xiv esl C aged ee te xiv Mechanical Installation 5 34 ez uou m rx rat ps ERR ES ERE RAO NE E eH xiv Special for ACx 6x7 Units from 315 to 630 KW esas er ER a rex xe XV Note o dose Duet gt nde e ITO e BE IR a o el XV Table of Contents Chapter 1 Introduction Generals ker gan Mek Ea AA A 1 1 Other Manuals DEM 1 1 Delivery Check 2 222 252 C M PPETT 1 2 ACK 6x4 6x7 Type Code soos ese aia e da da SA RPEEAO SR taxed ES 1 2 IDG IS Conus eens nae tate NR ge relia ee aod e ard es ro Box edet oa ud cr toT LEE 1 3 Chapter 2 Mechanical Installation Fastening the Cabinet to the Floor i245 vb EE REX Rich head Poh ee EA a Ee Roe re Rte Sepa 2 1 Fastening Clamps lt a es mutatus voee OSEE AR ERI SES 2 2 Holes inside th Cabihet 2 ea ES ace D ROCCO SEA RT m CR OR ORC EAR C E 2 2 ACS ACC ACP 604 6x7 Hardware Manual xvii Chapter 3 Electrical Installation INSULAT
76. nd ACx 6x7 with 50 Hz and 60 Hz supplies are below ACx ACS ACC ACP The 690 V series and 2 x R8 and 2 x R9 frame sizes are not available for ACP 600 See the next page for symbols Normal Use Heavy duty Use Duty Cycle Duty Cycle Duty Cycle Frequency 1 5 min 1 5 min 2 15 s Frame Converter Size Type bw hwNmax Sn PN Pu na endmax lana bnamax Sha Pha Pha 4 5min 1 5min 4 5min 1 5min 13 15s 2 15s A A IkVA kW HP A A A A KVA kW HP Three phase supply voltage 380 V 400 V or 415 V ACx 604 607 0100 3 147 162 100 75 100 112 168 112 224 70 55 75 R7 ACx 604 607 0120 3 178 196 120 90 125 147 221 147 294 100 75 100 ACx 604 607 0140 3 216 238 140 110 150 178 267 178 356 120 90 125 R8 ACx 604 607 0170 3 ACx 604 607 0210 3 260 286 170 132 200 1216 324 216 432 140 110 150 316 348 210 160 250 1260 390 260 520 170 132 200 ACx 604 607 0260 3 ACx 604 607 0320 3 395 435 260 200 300 316 474 316 632 210 160 250 R9 480 528 320 250 350 395 593 395 790 260 200 300 ACx 604 6x7 0400 3 600 661 400 315 400 494 741 494 988 320 250 350 2xR8 ACx 604 6x7 0490 3 751 827 490 400 500 600 901 600 11200 400 315 400 2xR9 ACx 604 6x7 0610 3 912 11003 610 500 600 751 1127 751
77. ndent on the frequency These requirements are easily met with a copper or aluminium shield armour The minimum requirement of the motor cable shield of the ACx 600 is shown below It consists of a concentric layer of copper wires with an open helix of copper tape The better and tighter the shield the lower the emission level and the bearing currents Insulation jacket Copper wire screen Helix of copper tape Inner insulation Cable core ACS ACC ACP 604 6x7 Frequency Converters 3 3 Chapter 3 Electrical Installation Special for Types For compliance with the European Union EMC Directive the ACx 6x7 ACx 6x7 0400 3 0490 5 must be installed with screened power cables specified below For and 0490 6 and up information on other equivalent cables please contact your local ABB distributor Motor Cable The motor cable used in the ACx 6x7 frequency converter installation must be a symmetrical three conductor screened cable in order to fulfil the radiated emission requirements stated in the generic emission standard for industrial environment EN 61800 3 The cable types MCCMK and AMCCMK from NK Cables Finland and VUSO and VO YMvK as from DRAKA KABEL have been tested and approved by ABB Industry Equivalent cables from other manufacturers that fulfil the requirements can be used in the installation of ACx 6x7 as well The suitability of a cable type can be decided on the grounds of either screen construction or t
78. ng Time Output Rising Time 3 ms Application Program Updating Time Standard 5 x 24 or 100 ms Standard 6 x 24 ms Crane 44 ms Motion Control 8 ms Digital Inputs ACS ACP 600 Six Programmable Digital 12 Programmable Digital Inputs Common Inputs Common Ground 24 VDC 15 to Ground 24 VDC 15 to 20 O 02 Logical Thresholds lt 8 VDC 0 ACC 600 Six Digital Inputs Common gt 12VDC amp 1 Ground 24 VDE 15 to 20 Filtering Time Constant lt 50 us Logical Thresholds lt 8 VDC 0 DI 11 and DI 12 can be used for time gt 12 VDC 1 measurement between two external events Input Current DI1 to DI 5 10 mA DI6 5mA PROBE1 and PROBE2 Filtering Time Constant 1 ms Internal Supply For Digital Inputs Thermistor Input 5 mA lt 1 5 kQ 2 1 24 VDC Short circuit proof group isolated normal temperature gt 4 kQ 0 high Isolation Test Voltage 500 VAC 1 minute temperature Open Circuit 0 high Input Updating Time 1 ms temperature m An external 24 VDC supply can be used Internal Supply For Digital Inputs instead of the internal supply 24 VDC Short circuit proof group isolated i Filtering Time Constant lt 100 us Isolation Test Voltage 500 VAC 1 minute Input Updating Time Application Program Updating Time Standard 5 x 12 ms Standard 6 x 6 ms Crane 44 ms Motion Control 4ms An external 24 VDC supply can be used instead of the internal supply Digital Outputs
79. nnected via an NPCU RS 232 485 converter to the panel connector on the cover or to modular jack X19 on the NAMC 11 51 board Observe colouring codes when installing fibre optic cables Blue connectors should go to blue terminals and grey connectors to grey terminals In case multiple modules are installed on the same channel they must be connected in a ring 3 20 ACS ACC ACP 604 6x7 Frequency Converters Connection Examples Fieldbus Adapter Module SOSSSOSSS RXD TXD SOSSSSSDS The terminals for the power supply connection vary Consult adapter module manual Chapter 3 Electrical Installation ACx 600 NAMC NIOC NIOCP TTS SS STS vo 31 il cm cHo DCO Th TE 6966605668555 Ssssess S SS SOS SOS NIOC Terminal X23 ke NIOCP Terminal X4 C 1 O Extension Module Pulse Encoder Module with ACS 600 Crane System Master Follower and Template Application Programs SSOSSSSSO RXD TXD SSOSSSSSOS The terminals for the power supply connection vary Consult module manual ACx 600 NAMC NIOC HC EL Gea EI 31 i cim NDC T m SSSSSSSSSSSS ssesos SS SS SOS SOS NIOC Terminal X23 L Not supported by ACP 600 ACS ACC ACP 604 6x7 Frequency Converters 3 21 Cha
80. not be attempted as overvoltages can result in permanent damage to the ACx 600 vi ACx ACS ACC ACP ACS ACC ACP 604 6x7 Frequency Converters Safety Instructions Earth Ground Fault The ACx 600 is equipped with an internal earth fault protective function Protective Function to protect the unit against earth faults in the inverter the motor and the motor cable This is not a personal safety or a fire protection feature The earth fault protective function can be disabled by Parameter 30 17 EARTH FAULT Standard Application Program and Parameter 30 11 Crane Application Program The internal earth fault protective function is not in use in the 12 pulse supplied units For ACS 62x units refer to subsection Special for ACx 6x7 Units from 315 to 630 kW The EMC filter of the ACx 600 includes capacitors connected between the main circuit and the frame These capacitors increase the earth ground leakage current through the PE connector to the mains line which may cause some fault current circuit breakers to function Power Loss Ride through Function WARNING When equipped with a main contactor option the drive also includes a Power Loss Ride through function which keeps the N drive control live during during a short main supply break If this function is not safe for your prosess inactivate it according to the instructions given in ACS ACC ACP 607 Contactor Option Information on the Power Loss Ride through Function EN c
81. o improve local equalizing of potential Below is a diagram of cable routing Mains cable Motor cable f min 500 mm Control cables ACS ACC ACP 604 6x7 Frequency Converters 3 7 Chapter 3 Electrical Installation Mains Motor and A view of the recommended earthing mains and motor cable Control Cable connections of the ACx 607 types 0320 3 and 0400 5 6 and smaller Connection is presented below F denotes a 360 degrees earthing Max 6 control cables Li L2 L3 PE I I ACx 607 BN i Frequency l Converter U1 V1 wij 0 em sel v jog 4 A F c _ IDEE X2 d option mm gt L EMC Line Filter NIOC NIOCP NAMC PE Line Options 2 3 8 os 4 THE A EN SANT MA NIOC NIOCP amp NAMC T41 rre ACx 604 Converter Unit ES UDC UDC U2 v2 w2 I I r du dt Filter I I I Common Mode Filter 3 7 9 i b I 1 used if the conductivity of the cable screen is lt LL 4 50 96 of the conductivity of the phase conductor d 11 2 used
82. ode 64354949 Emergency Stop Emergency stop devices must be installed at each operator control Devices station and at other operating stations where emergency stop may be required Pressing the key on the Control Panel of ACx 600 does not generate an emergency stop of the motor or separate the drive from dangerous potential Line Contactor and Emergency Stop Switch are factory installed as option for ACx 6x7 ACS ACC ACP 604 6x7 Frequency Converters ACx ACS ACC ACP vii Safety Instructions Motor Connections A Pulses in the Drive Output Protecting the Motor Winding Protecting the Motor Bearings Requirements Table WARNING Operation is not allowed if the motor nominal voltage is less than 1 2 of ACP 0 4 times the ACx 600 nominal input voltage or the motor nominal current is less than 1 6 of the ACx 600 nominal output current lnd As with all frequency converters employing the most modern IGBT inverter technology the ACx 600 output comprises regardless of output frequency pulses of approximately 1 35 times the mains network voltage with a very short rise time The voltage of the pulses can be almost double at the motor terminals depending on the motor cable properties This in turn can cause additional stress on the motor insulation Modern variable speed drives with their fast rising voltage pulses and high switching frequencies can cause current pulses through the motor bearings which can gradually
83. of the Equipment or any associated equipment cost of capital cost of substitute equipment facilities or services downtime costs delays or claims of customers of the Purchaser or other third parties for such or other damages ABB s liability on any claim whether in contract warranty negligence tort strict liability or otherwise for any loss or damage arising out of connected with or resulting from the contract or the performance or breach thereof or from the design manufacture sale delivery resale repair replacement installation technical direction of installation inspection operation or use of any equipment covered by or in connection therewith shall in no case exceed the purchase price of the Equipment or part thereof or services which give rise to the Claim All clauses of action against ABB arising out of or relating to the contract or the performance or breach hereof shall expire unless brought within one year of the time of accrual thereof In no event regardless of cause shall ABB assume responsibility for or be liable for penalties or penalty clauses of any description or for indemnification of customer or others for costs damages or expenses each arising out of or related to the goods or services of the order Your local distributor or ABB office may hold different guarantee details which are specified in the sales terms conditions or guarantee terms These terms are available on request If you have any que
84. on the motor cable when common mode filter is required ACS ACC ACP 604 6x7 Frequency Converters 4 1 Chapter 4 Installation Checklist OO 0 0 O O INSTALLATION CHECKLIST Check that motor connections at U2 V2 and W2 are OK Check motor cable routing Check that there are no power factor compensation capacitors in the motor cable Check that control connections inside the frame are OK Check that options such as PTC PT100 relays cubicle heater motor fan starter etc are wired inside the cabinet See the circuit diagrams delivered with the unit In ACx 627 types 0400 3 and 0490 5 6 and up not equipped with main contactors check the wiring for switching off the mains supply in case of a fuse failure and an earth fault See Safety Instructions Check that there are no tools or other foreign objects inside the cabinet With bypass connection check that mains voltage cannot be applied to the output of the ACx 600 4 2 ACS ACC ACP 604 6x7 Frequency Converters Chapter 5 Maintenance undertaken by a qualified electrician only The Safety Instructions on A WARNING All maintenance work described in this chapter must be the first pages of this manual must be followed Heatsink The ACx 600 can run into overtemperature Faults if the heatsink is not clean In normal environment the heatsink should be checked and cleaned annually Use compressed air to remove dust from the heatsink The a
85. pter 3 Electrical Installation Connection Examples Pulse Encoder Module NTAC with l ACS 600 Standard Application Program ACS 600 NAMC NIOC 1 A CT CONDO OQOSSOSOSOSS 1 CH2 CH1 TE TE RXD 159808905050 PYS S SSNS ses Ses TxD NIOC Terminal X23 ES MAIN A utu Ru SOSOSOSSSS The terminals for The ACP 600 supports the the power supply NTACP Double Pulse connection vary Encoder instead See NTACP Consult module Installation and Start up manual Guide C Drive Window gt ACx 600 NAMC NIOC A NIOCP CH3 CH1 ee Th TE EZ G ISIS Sos SSG SOS Laptop PC na na E u Y if NO NDPC NISA NDPA LZ Desktop PC ESTA MN Sn 3 22 ACS ACC ACP 604 6x7 Frequency Converters Chapter 3 Electrical Installation Installation of Other Install options such as PTC PT100 relays cubicle heater motor fan Optional Equipment starter etc according to circuit diagrams delivered with the unit ACS ACC ACP 604 6x7 Frequency Converters 3 23 Chapter 3 Electrical Installation 3 24 ACS ACC ACP 604 6x7 Frequency Converters Chapter 4 Installation Checklist Installation Checklist The ACx 600 mechanical and electrical installation should be checked before start up It is advisable to go through
86. quipment is up to these conditions WARNING There are several automatic reset functions in the ACS 600 with Standard Application Program If selected they reset the unit and resume operation after a fault These functions should not be selected if other equipment is not compatible with this kind of operation or dangerous situations can be caused by such action WARNING If an external source for start command is selected and it is ON the ACS 600 with Standard Application Program will start immediately after fault reset ACS ACC ACP 604 6x7 Frequency Converters ACx ACS ACC ACP xi Safety Instructions Power Factor Power factor compensation capacitors and surge absorbers must not Compensation be connected to the motor cables These devices are not designed to Capacitors be used with frequency converters and will degrade motor control accuracy They can cause permanent damage to the ACx 600 or themselves due to the rapid changes in the ACx 600 output voltage If there are power factor compensation capacitors in parallel with the ACx 600 make sure that the capacitors and the ACx 600 are not charged simultaneously to avoid voltage surges which might damage the unit Output Contactors f a contactor is used between the output of the ACx 600 and the motor with DTC control mode selected the output voltage of the ACx 600 must be controlled to zero before the contactor is opened Otherwise the contactor will be damage
87. racy 11 bit Inaccuracy 0 1 Full Scale Range at 25 C Temperature Coefficient 100 ppm C max Input Updating Time 1 ms Constant Voltage Output Voltage 10 VDC 0 5 Full Scale Range at 25 C Temperature Coefficient 100 ppm C max Maximum Load 10 mA Applicable Potentiometer 1 kO to 10 kQ Voltage 10 VDC 0 5 Full Scale Range at 25 C Temperature Coefficient 100 ppm C max Maximum Load 10 mA Applicable Potentiometer gt 1 KQ Auxiliary Power Output Voltage 24 VDC 10 Short circuit proof Maximum Current 250 mA 130 mA with NLMD 01 option Voltage 24 VDC 10 Short circuit proof Maximum Current 300 mA ACS ACC ACP 604 6x7 Frequency Converters Appendix A ACS ACC ACP 604 6x7 Technical Data ACS ACC ACP 600 ACP 600 NIOC 01 Board NIOCP 01 Board Analogue Outputs ACS ACC 600 Two Programmable Current One Bipolar Programmable Voltage Output Outputs 0 4 to 20 mA AL lt 700 Q 10V R gt 2k0 ACP 600 One Programmable Current Resolution 0 02 95 12 bit Output 0 to 20 mA R 700 Q Accuracy 10 bit Resolution 0 1 10 bit Inaccuracy 0 1 Full Scale Range at Inaccuracy 1 Full Scale Range at 25 C Temperature Coefficient 25 C Temperature Coefficient X 200 ppm C max O 200 ppm C max Output Updating Time 2 ms Output Updati
88. ransfer impedance The general rule for the cable screen effectiveness is the better and tighter the screen of the cable the lower the radiated emission level There are two kinds of cable screen constructions that fulfil the minimum requirement of screen effectiveness a screen consisting of a layer of copper tape overlapping each round and a concentric layer of copper wires figure a below or a screen consisting of a braided galvanised steel wire item b below Spiral wrapped Wrapped copper Insulation jacket copper wire screen tape Inner insulation Cable core Tape overlap Insulation jacket Braided metallic screen Inner insulation e Cable core ACS ACC ACP 604 6x7 Frequency Converters Chapter 3 Electrical Installation Mains Cable The mains cable used in the installation must be a three or four conductor screened cable The cable types MCMK and AMCMK from NK Cables have been tested and approved by ABB Industry The mains cable screen of an equivalent cable must at least consist of a concentric layer of copper wires with an open helix of copper tape connecting the wires together and reducing the size of the holes in the screen figure on page 3 3 However motor cables with better shielding eg braided screen emit considerably less high frequency interference ACS ACC ACP 604 6x7 Frequency Converters 3 5 Chapter 3 Electrical Installation Control Cables Relay C
89. re 5 1 WARNING The converter supply must be disconnected while the reforming circuit is connected DC Power Supply Disconnect from supply 1 35 U4 Converter R 100 Ohm 500 W 5 4 ACS ACC ACP 604 6x7 Frequency Converters Control Panel Connection Chapter 5 Maintenance The Control Panel is connected to modular jack X19 on NAMC 11 51 board The modular jacks on the NIOC board are not intended for Panel use they are used by Standard Modbus Link E CH2 CH1 SH INT BRO g Spacer xi gt Spacer X19 au LEDs V16 V15 The table below shows the indications of the LEDs on the control V12 V11 on NAMC 51 for optional Memory Backup board NMBO NAMC 1 1 51 Component Side Down boards Control Board LED When the LED is lit NAMC Green V4 The power supply of the board is OK Red V18 Fault Red V5 not in _ use NINT Green V14 The board is powered NIOC Green V5 The power supply of the board is OK Red V6 Fault NPOW Green V4 The board is powered ACS ACC ACP 604 6x7 Frequency Converters Chapter 5 Maintenance ACS ACC ACP 604 6x7 Frequency Converters Appendix A ACS ACC ACP 604 6x7 Technical Data IEC Ratings The IEC ratings for ACx 604 a
90. relative humidity is 6096 in the presence of corrosive gases Contamination Levels IEC 721 3 3 No conductive dust allowed Boards without coating Chemical gases Class 3C1 Solid particles Class 3S2 Boards with coating Chemical gases Class 3C2 Solid particles Class 3S2 Boards without coating Chemical gases Class 1C2 Solid particles Class 1S3 Boards with coating Chemical gases Class 1C2 Solid particles Class 1S3 Boards without coating Chemical gases Class 2C2 Solid particles Class 252 Boards with coating Chemical gases Class 2C2 Solid particles Class 252 Atmospheric 70 to 106 kPa 70 to 106 kPa 60 to 106 kPa Pressure 0 7 to 1 05 atmospheres 0 7 to 1 05 atmospheres 0 6 to 1 05 atmospheres Vibration Max 0 3 mm 0 01 in Max 1 5 mm 0 06 in Max 3 5 mm 0 14 in IEC 68 2 6 2 to 9 Hz 2 to 9 Hz 2 to 9 Hz max 1 m s 3 3 ft s max 5 m s 16 4 ft s max 15 m s 49 ft s 9 to 200 Hz sinusoidal 9 to 200 Hz sinusoidal 9 to 200 Hz sinusoidal Shock Not allowed Max 100 m s 330 ft s Max 100 m s 330 ft s IEC 68 2 29 11 ms 11 ms Free Fall Not allowed 250 mm 10 in for weight 250 mm 10 in for weight under 100 kg 220 Ibs under 100 kg 220 lbs 100 mm 4 in for weight over 100 mm 4 in for weight over 100 kg 220 Ibs 100 kg 220 Ibs 1 At sites over 1000 m 3300 ft above sea level the maximum output current
91. ring refer to Table A 1 when installed to IT networks The mains becomes connected to earth potential through the EMC filter capacitors In IT networks this may cause danger or damage the unit General ABB warrants the Equipment supplied by ABB against defects in material and workmanship for a period of twelve 12 months after installation or twenty four 24 months from date of shipment from factory whichever first occurs Should any failure to conform with the applicable warranties appear during the specified periods under normal and proper use and provided the Equipment has been properly stored installed operated and maintained and if given prompt notice by Purchaser ABB shall correct such nonconformity at its option by 1 repair or replacement of the nonconforming equipment or parts thereof Repairs or replacements pursuant to warranty shall not renew or extend the applicable original equipment warranty period provided however that any such repairs or replacement of equipment or parts thereof shall be warranted for the time remaining of the original warranty period or 30 days whichever is longer ABB shall not be responsible for providing working access to the defect including disassembly and reassembly of equipment or for providing transportation to and from repair or factory facility all of which shall be at Purchaser s risk and expense These warranties shall not apply to any Equipment or parts thereof which 1 have been imp
92. roperly repaired or altered 2 have been subjected to misuse negligence or accident 3 have been used in a manner contrary to ABB s instructions 4 are comprised of materials provided or designed stipulated by Purchaser or 5 are used equipment The foregoing warranties are exclusive and in lieu of all other warranties of quality and performance written oral or implied and all other warranties including any implied warranties of merchantability or fitness for a particular purpose are hereby disclaimed by ABB and all equipment manufacturers Correction of nonconformities in the manner and for the period of time provided above shall be the Purchaser s exclusive remedy and shall constitute fulfilment of all liabilities of ABB and any Equipment manufacturer including any liability for direct indirect special incidental or consequential damages whether in warranty contract negligence tort strict liability or otherwise with respect to any nonconformance of or defect or deficiency in the equipment supplied or services furnished hereunder ACS ACC ACP 604 6x7 Frequency Converters A 31 Appendix A ACS ACC ACP 604 6x7 Technical Data Limitation of Liability IN NO EVENT SHALL ABB ITS SUPPLIERS OR SUBCONTRACTORS BE LIABLE FOR SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES WHETHER IN CONTRACT WARRANTY TORT NEGLIGENCE STRICT LIABILITY OR OTHERWISE including but not limited to loss of profits or revenue loss of use
93. rthed via a separate PE conductor or via cable screen 3 used only if local safety regulations do not accept earthing of the ACx 600 and the motor merely through the cable screen Note Connecting the fourth conductor of the cable at the motor increases bearing currents thus causing extra wear ACS ACC ACP 604 6x7 Frequency Converters 3 13 Chapter 3 Electrical Installation Transformer Settings Mains Fuse Supervision ACx 627 Earth Fault Detection Note To connect the mains and motor cables for ACx 6x7 frame sizes 2 x R8 and 2 x R9 carry out the following procedure 1 Make sure that the ACx 6x7 is disconnected from the mains network during installation The switch fuse with handle in the front door of the ACx 6x7 does not switch off power from the EMC Line Filter Disconnect the ACx 6x7 with EMC Line Filter from the mains network at the distribution board Wait for 5 minutes before working on the frequency converter the motor or the motor cable 2 Open the cabinet door 3 If EMC Line Filter is used check that there is no voltage in its output terminals measure the voltage from one terminal against the two other terminals and from terminal to earth 4 Remove the emission shields and shrouds 5 Go to point 5 on page 3 9 Connect the earthing common mode filter mains and motor cables 1 Both converter units include a transformer designation T41 which supplies the cooling fan at the base of the unit as wel
94. s power 2 Open the cabinet door 3 Open the hinged assembly plate to gain access to the mains and Earthing Connections 6 motor cable terminals Measure the voltage between each input terminal U1 V1 W1 and earth with a multimeter impedance at least 1 MQ to ensure that the frequency converter is discharged Lead the cables inside the cabinet through the EMC sleeves If cable entry is not possible otherwise remove the lead through plate and slide it onto the cable After the earthing connections are done fasten the lead through plate P 54 and cable entry from above Remove the rubber grommets from the lead through plates and cut them to adequate diameter for the mains and the motor cable To ensure proper sealing cut along the diameter marking that corresponds to the cable diameter Slide the grommet onto the cable Strip the cable according to the figure below For IP 54 units and cable entry from above add a rubber grommet on the cable under above the lead through plate Tighten the EMC sleeve on the bare cable screen with cable ties 8 Twist the screen wires together to a pigtail and connect to the PE terminal of the cabinet ACS ACC ACP 604 6x7 Frequency Converters 3 9 Chapter 3 Electrical Installation Cable shield PE terminal Strain relief lt Strip this part of the cable RE KR RED MR 2121712721772 Base plate 10 11 12 Lead through plate
95. stions concerning your ABB frequency converter please contact the local distributor or ABB office The technical data information and specifications are valid at the time of printing The manufacturer reserves the right to modifications without prior notice A 32 ACS ACC ACP 604 6x7 Frequency Converters AA EP ED P EP I 3AFY 61201394 R0525 REV D EFFECTIVE 15 6 2001 EN ABB Industry Oy Drives P O Box 184 FIN 00381 HELSINKI FINLAND Telephone 358 10 22 2000 Telefax 358 10 22 22681 Internet http www abb com automation ABB Automation Inc Drives amp Power Products 16250 West Glendale Drive New Berlin WI 53151 USA Telephone 262 785 8378 800 243 4384 Telefax 262 780 5135
96. tage by up to 20 percent This should be taken into consideration when determining the motor insulation requirement Example Motor insulation requirement for a 400 V application must be selected as if the drive were supplied with 480 V Note 5 This table applies to NEMA motors with the following heading PN lt 134 HP 134 HP Py lt 469 HP Py gt 469 HP and Frame Size NEMA 500 or Frame Size NEMA 500 X ACx ACS ACC ACP ACS ACC ACP 604 6x7 Frequency Converters Safety Instructions Note 6 Calculating the Rise Time and the Peak Line to line Voltage The peak line to line voltage at the motor terminals generated by the ACS 600 as well as the voltage rise time depend on the cable length The requirements for the motor insulation system given in the table are worst case requirements covering the ACS 600 installations with 30 metre and longer cables The rise time can be calculated as follows At 0 8 du dt Read and du dt from the diagrams below 4 4 3 5 T 3 5 37 31 F 2 5 7 25 U UN 2 hu 2 ul u du dt kV us 151 a 157 1T 17 du dt kV us 051 05 o l 07 0 t H 0 100 200 300 400 0 100 200 300 400 Cable length m Cable length m Without du at Filter With du at Filter WARNING The ACx 600 introduces electric motors drive train mechanisms and driven machines to an extended operating range It should be determined from the outset that all e
97. tarter for Auxiliary Motor Fan 20 Filters Appendix A 0 with EMC Filters not for 690V or 12 pulse rectifier CE marking 3 with output du dt Filters EMC Filters not for 690V 5 Output du dt Filters no EMC Filters 8 No CE no EMC filters US conduit ACS 607 only 115 VAC transformer secondary compliant with NFPA 90 9 without EMC Filters A Common Mode Filter B Common Mode Filter EMC Filter not for 690V C du dt Filter Light Common Mode filter D du dt Filter Light Common Mode filter EMC Filter not for 690V E du dt Filter Common Mode Filter F du dt Filter Common Mode Filter EMC Filter not for 690V G Light Common Mode Filter 21 ACx 607 Braking Chopper and Cabling Direction ACx 604 R NDCU control unit outside the module 0 NIOC and NAMC boards inside the module 22 Other Options Inquiries Any inquiries about the product should be addressed to the local ABB representative quoting the type code and the serial number of the unit If the local ABB representative cannot be contacted inquiries should be addressed to ABB Industry Helsinki Finland ACS ACC ACP 604 6x7 Frequency Converters 1 3 Chapter 1 Introduction 1 4 ACS ACC ACP 604 6x7 Frequency Converters Fastening the Cabinet to the Floor Chapter 2 Mechanical Installation See Appendix A ACS ACC ACP 604 6x7 Technical Data for allowed operation conditions of the ACx 604 6x
98. tation is used throughout the manual Dangerous Voltage WARNING warns of situations in which a high voltage can cause physical injury and or damage equipment The text next to this symbol describes ways to avoid the danger General WARNING warns of situations which can cause physical injury and or damage equipment by means other than electrical The text next to this symbol describes ways to avoid the danger Electrostatic Discharge WARNING warns of situations in which 4 an electrostatic discharge can damage equipment The text next to Arad this symbol describes ways to avoid the danger CAUTION Aims to draw special attention to a particular issue Note Gives additional information or points out more information available on the subject ACS ACC ACP 604 6x7 Frequency Converters ACx ACS ACC ACP iii Safety Instructions Installation and Maintenance Safety A These safety instructions are intended for all work on the ACx 604 607 627 Neglecting these instructions can cause physical injury and death WARNING All electrical installation and maintenance work on the ACx 600 should be carried out by qualified electricians Do not attempt any work on a powered ACx 600 After switching off the mains always allow the intermediate circuit capacitors 5 minutes to discharge before working on the frequency converter the motor or the motor cable The voltage between each input terminal U1 V1 W1 and earth must be measured
99. ted depending on the use normal heavy duty or pump and fan respectively Input power and motor cable terminal wire size capabilities and tightening torques for the ACS ACC ACP 604 6x7 are in the table below The capability is specified based on wire lug that the terminal accepts according to DIN 46234 for copper cables and DIN 46329 for aluminium cables cable cross section that will fit through the European lead through plate hole and maximum electrically needed European cable cross section NEMA two hole lugs 1 2 inch in diameter and 1 75 inches on center can be used in frame sizes R8 and R9 and R7 output Terminal kit crush down connection This kit is used in frame size R7 frequency converters input cable terminal and includes screws The conductor is plugged into the kit without a cable lug 1X120 Maximum cable cross section in mm Maximum number of cable connections Bus bar connection with hole requiring bolt washer nut and wire lug to be supplied by others The other style connection using the same reference is an insulated stud connection washer and nut The wire lug is provided by others 1X 10 120 Maximum cable cross section in mm E Diameter of maximum bolt that will fit through the hole in the bus bar or stud connection in mm p Maximum number of cable connections Ifan M is added before the number in the table e g M10 we have a designator for a standard metric
100. the checklist below together with another person Study carefully the Safety Instructions on the first pages of this manual before attempting any work on or with the unit O O MECHANICAL INSTALLATION ELECTRICAL INSTALLATION see Chapter 3 Electrical Installation INSTALLATION CHECKLIST Check that the ambient operating conditions are allowable See Appendix A environmental limits cooling air flow requirements free space requirements Check that the unit is fixed properly See Chapter 2 Mechanical Installation Check that cooling air flows freely Check the applicability of the motor and the driven equipment See Appendix A Motor Connection Ifthe ACx 600 is connected to unearthed mains check that the EMC filter capacitors are disconnected Check that the converter unit is earthed properly Check that the mains voltage matches the frequency converter nominal input voltage In the ACx 607 except frame R7 and the ACx 604 check that the setting of the transformer T41 corresponds to the supply voltage In ACx 6x7 types 0400 3 and 0490 5 6 and up check that the settings of the transformers T21 and T10 correspond to the supply voltage With line contactor option check that the setting of the internal transformer corresponds to the supply voltage Check that mains connections at U1 V1 and W1 are OK Check that appropriate mains fuses are installed Check that toroidal cores are properly installed
101. then 0 85 Ian or 0 85 lonsg Or 1 long ACS ACC ACP 604 6x7 Frequency Converters A 3 Appendix A ACS ACC ACP 604 6x7 Technical Data Input Power Connection Motor Connection Voltage U4 380 400 415 VAC 3 phase 10 for 400 VAC units 380 400 415 440 460 480 500 VAC 3 phase 10 for 500 VAC units 525 550 575 600 660 690 VAC 3 phase 10 for 690 VAC units Short Circuit Capability The rated short time withstand current of the ACx 600 is 50 kA 1 s Measured according to US standards up to 400 kVA Suitable for use in a circuit capable of delivering not more than 65 kA rms symmetrical amperes at 480 V maximum 500 V units and at 600 V maximum 690 V units Frequency 48 to 63 Hz maximum rate of change 17 s Imbalance Max 3 of nominal phase to phase input voltage Fundamental Power Factor cos q4 0 97 at nominal load Voltage U5 0 to U 3 phase symmetrical Frequency DTC mode 0 to 3 2 frwp Maximum frequency 300 Hz f _ Unmains f FWP USC Nmotor Nmotor fewp Frequency at field weakening point Unmains Mains input power voltage Unmotor Rated motor voltage fNmotor Rated motor frequency Scalar Control mode not for ACP 600 0 to 300 Hz With du dt Filter DTC and Scalar Control modes 0 to 120 Hz Frequency Resolution 0 01 Hz Current see rating tables Power Limit 1 5 Pha Overcurrent Trip 3 5 long Field Weakening Point 8 to 300 Hz Switching Frequency 3 kHz average
102. together as well as to the PE Normal use Ensure that the permanent magnet motor cannot rotate at too high a speed Overspeed leads to overvoltage which may explode the capacitors in the intermediate circuit of the drive Permanent magnet motor may be used with ACS 600 Permanent Magnet Synchronous Motor PMSM System Application Program or with other application programs in scalar control mode only Supply Connections ACx 6x7 units include an on load isolating switch fuse with handle in the front door This switch fuse does not switch off the power from the EMC Line Filter of ACS ACC 6x7 0400 3 0490 3 5 6 0610 3 5 6 and 0760 5 6 units For ACS ACC 6x7 0400 3 0490 3 5 6 0610 3 5 6 and 0760 5 6 units with EMC Line Filter and for the ACx 604 module a supply disconnecting device must be installed in the supply by which the electric parts of the unit can be separated from the mains power network during installation and maintenance work The supply disconnecting device must be locked to the open position during installation and maintenance work ACS ACC ACP 604 6x7 Frequency Converters ACx ACS ACC ACP V Safety Instructions To meet the European Union Directives the disconnecting device shall fulfil the requirements of EN 60204 1 chapter 5 3 3 and shall be one of the following types e aswitch disconnector in accordance with IEC 60947 3 utilization category AC 23B or DC 23B adisconnector in accordance with IEC 60947
103. ust be rated for the same voltage level as the converter main circuit ACS ACC ACP 604 6x7 Frequency Converters ACx ACS ACC ACP xiii Safety Instructions EMC Note If safety switches contactors connection boxes or similar equipment are used in the motor cable they should be installed in a metal enclosure with 360 degrees earthing for the screens of both the incoming cable and the outgoing cable or the screens of the cables should otherwise be connected together y WARNING The printed circuit boards contain integrated circuits that 4 are extremely sensitive to electrostatic discharge Exercise appropriate Arad care when working on the unit to avoid permanent damage to the circuits Do not touch the boards unnecessarily Cooling fulfilled Special attention must be paid to cooling if units are installed in confined spaces and user defined cabinets Air flow from below e g a cable conduit into the cabinet must be prevented This is essential for fire safety reasons and to retain the original degree of protection For best results use the lead through plates delivered with the unit N WARNING The cooling air flows and space requirements must be Mechanical CAUTION The ACx 6x7 should only be transported on the original Installation pallet or with a proper lifting device using the lifting lugs on top of the cabinet The frequency converter is not intended to be lifted by running lines under the unit T
104. version ACx 600 test date A 26 ACS ACC ACP 604 6x7 Frequency Converters Appendix A ACS ACC ACP 604 6x7 Technical Data Applicable Standards The ACS 600 complies with the following standards EN 60204 1 1992 Corr 1993 IEC 204 1 Safety of machinery Electrical equipment of machines Part 1 General requirements Provisions for compliance The final assembler of the machine is responsible for installing an emergency stop device a supply disconnecting device ACx 601 and ACx 604 the ACx 604 IP 00 into a separate casing EN 60529 1991 IEC 529 IEC 664 1 1992 Degrees of protection provided by enclosures IP code EN 61800 3 1996 EMC product standard including specific test methods AS NZS 2064 1997 Limits and methods of measurement of electronic disturbance characteristics of industrial scientific and medical radiofrequency equipment ACS 600 complies with the requirements given for class A equipment This standard is applied in Australia and New Zealand Materials Enclosure ACx 601 Pas Of Color PS polystyrene 3 mm NCS 1502 Y RAL 90021 PMS 420 C hot dip zinc coated steel sheet 1 5 to 2 mm painted 60 um NCS 8502 Y RAL 9004 PMS 426 C semigloss with epoxy polyester powder paint anodised aluminium profile R2 to R6 black ES 900 Enclosure ACx 604 6x7 hot dip zinc coated steel sheet 1 5 to 2 mm with 60 um RAL 7035 polyester thermosetting powder coating Package ACx 604
105. wing Connecting Procedure procedure Side view Top view Lead through plate AC T NA Holes for Pn position screws EMI conductive cushions Special for Top Entry When each cable has its own rubber grommet sufficient IP and EMC protection can be achieved However if very many control cables come to one cabinet plan the installation beforehand as follows 1 Make a list of the cables coming to the cabinet 2 Sort the cables going to the left into one group and the cables going to the right into another group to avoid unnecessary crossing of cables inside the cabinet 3 Sort the cables in each group according to size 4 Group the cables for each grommet as follows Cable diameter in mm Max number of cables per grommet 13 4 17 3 25 2 225 1 ACS ACC ACP 604 6x7 Frequency Converters 3 15 Chapter 3 Electrical Installation 5 Divide the bunches so that the cables will be arranged according to size between the EMI conductive cushions View from below fi feb EO o3 aw Thinnest cable Gr q Thickest cable N Bottom and Top Entry Proceed as follows 1 2 Loosen the ead through plate position screws Pull the two parts apart Bottom entry Lead the cable inside the cabinet through the EMI conductive cushions Top entry Lead the cable inside the cabinet through t
106. with Standard and Pump and Fan Control Application Programs typically achieved motor power with lonsq Heavy duty use 50 or 100 overload capacity bon rated rms output current long rated rms output current loNmax rms overload current allowed for one minute lohdmax rms overload current allowed for one minute every 5 minutes every 5 minutes or 2 seconds every 15 loNmax 1 5 min 1 1 by seconds Maximum current depends on parameter setting refer to Firmware Manual bhdmax 1 5 min 1 5 long londmax 2 15 s 2 0 long 400 and 500 VAC units or 1 5 long 690 VAC units SN rated apparent output power Shd rated apparent output power PN typical motor power The power ratings in kW Pad typical motor power The power ratings in kW Pump and Fan Use Squared Load no overload capacity bNsq apply to most IEC 34 motors The power ratings in HP apply to most four pole NEMA rated motors rated rms output current apply to most IEC 34 motors The power ratings in HP apply to most four pole NEMA rated motors A 2 ACS ACC ACP 604 6x7 Frequency Converters NEMA Ratings Output Current Appendix A ACS ACC ACP 604 6x7 Technical Data The NEMA ratings for ACS 604 and ACS 607 with 60 Hz supply are below Symbols are described on the previous page Normal Use Heavy duty Use Duty Cycle Duty Cycle Duty Cycle 1 5 min 1 5 min 2 15s ACS 604 607 Frame Type bn lonmax PN lona bndmax ahd
107. with a multimeter impedance at least 1 MQ to ensure that the frequency converter is discharged before beginning work All insulation tests must be carried out with the ACx 600 disconnected from the cabling The ACx 600 motor cable terminals are at a dangerously high voltage when input power is applied regardless of motor operation No work on the motor cable should be attempted with mains power applied The brake control terminals UDC UDC R and R terminals carry a dangerous DC voltage over 500 V There can be dangerous voltages inside the ACx 600 from external control circuits when the ACx 600 input power is shut off No work on the control cables should be attempted when power is applied to the frequency converter or to the external control circuits Exercise appropriate care when working with the unit ACx ACS ACC ACP ACS ACC ACP 604 6x7 Frequency Converters Safety Instructions Permanent Magnet Installation and maintenance work A When a permanent magnet motor is connected to the drive ensure that the driven machine cannot rotate the motor during installation and maintenance work When rotating the permanent magnet motor feeds power to the intermediate circuit of the drive and also the supply connections become live even when the inverter is stopped Disconnect the motor from the drive with a safety switch or lock the motor shaft and earth the motor connection terminals temporarily by connecting them

ACS600 Hardware Manual, ACS/ACC/ACP 604/607/627, Frequency

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