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ABB ACS800-01 & ACS800-U1 Drives Hardware Manual

1. 827 Z An lt L U U X RZ GI N N y LI 5 f Y W 1 10 1 Ps os x gt e ae N GA o MH lt 1 w K i a 1i L M Nj o 5 N E A 8 SK R E ay S el C o ul U S 8 E in lp amp g S el m yN m m YS gt z o o o j 3 p b c 9 Ss S L e 611577 o 0 91 807 LI 821 Z amp 4 BD A if f A A a ree 7 L CyS SL ber A l 1 LI FAN o R br zzz po a z o oo ool B i o O 3 a 00000 A S 8 __J 00000 1 2 E 4 A A A ed 5 nT 827 fires r 7 era eit 8781 017 T F EL S l La ERE OE EER D 8107 825 8 o o SA S S o st Dimensional drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 122 Frame size R4 IP 21 UL type 1 m amp S pa M 10 SI EP UW LO N N N o NA a ym N R y M TS RE r ES
2. 1 R t0 A I i LOJ TI m r o N Y E E 3 3 5 y S Y BE Y mM 2 La 5 SETT 8 o o 3 3 Dimensional drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 120 Frame size R3 IP 21 UL type 1 en N X N E gt gt r A m Sc 7 e a W A MS T y gt T J 1 16917 Oty z 00 Ly N 8 A a ll M AS a HO SN x m oll s 8 L MI y ES NUI E i NI S poe Je a A o S o o Dimensional drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 121 Frame size R3 IP 55 UL type 12
3. X20 1 VREF 2 AGND X21 1 VREF 2 AGND 3 Al1 4 AM Common mode voltage between E BOT channels 15 V 6 Al2 7 AI3 8 AI3 9 AO1 10 AO1 11 AO2 12 AO2 x22 1 DI1 2 DI2 3 DI3 k u DE Jumper J1 settings 9 DGND1 5 DIS 1 JA All digital inputs share a common 6 DI6 B M ground This is the default setting 7 24VD 8 24VD 71 Grounds of input groups 1 DIIL Pl DI1 DI4 and DI5 DI6 DIIL er L are separate insulation 9 DGND2 u voltage 50 V X23 24 V 2 GND 5 X25 RO1 2 RO1 teet 3 RO1 X26 RO2 2 RO2 3 RO2 X27 RO3 RO3 lt 3 RO3 Test voltage 4 kV AC Ground Motor control and I O board RMIO Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 79 Installation checklist Checklist Check the mechanical and electrical installation of the drive before start up Go through the checklist below together with another person Read the Safety instructions on the first pages of this manual before you work on the unit Check MECHANICAL INSTALLATION O The ambient operating conditions are allowed See Mechanical installation Technical data IEC data or NEMA data Ambient conditions A The unit is fixed prop
4. r T S 91 ocv i i m Jn m ET M 00 N s o SN 15 E 1 lt RRS Je Cpe LOIN 1 i N E 8 i d a o S y e ES 1 us E Br 81 077 r N lt 2 x 3 Dimensional drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 133 Frame size R3 UL type 12 IP 55 sc Z M m lt I LN RI e S rj E o E a Q ef YD i a i y o a o PLU o o O a 1091 80 S B A vez c9 1 7391 007 i rq a rel cj O O 4 i EN lt 2 OOO OO o 878 017 e lt o 8L 0z 875 S o g 3 Dimensional drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 134 Frame size R4 UL type 1 IP 21
5. A O 0 00 o o 00000 00000 ABB ZN s o o te o ao e o o lt 5 lt 3 Dimensional drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 140 Frame size R6 UL type 12 IP 55 A m FANE JE o o o m QA o ao e 7 s o y o 6 5 s lo o 1 U LI d U a O57 Oz NI Y 1837 939 717 007 u ims U U U U U ATR BI pome a n C END jo o oo 00 8 s lt LL 90008 1 B pa 20 A f 19 A n 5 lt 7 E S o G y o Dimensional drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Frame size R6 UL type 12 IP 55 0205 3 and 0255 5 units p Lus 3 De NA H ed m H 5 a M 2 EMIT 2 S m S eo y E a al O ga j v x mE 2 5815 a F Li O zla SES ce el cul cul ed 1 lt S 0 e 3 8611 v d 3
6. d g li M NI 5 EN EN N L 3 Se EN 2 g 449 d 2 amp Le x m 5 e e Ek ee ki JL Me 93 s9 a N x 1 al 9 M AE o s o zm 0781 Sv E aS A 5 40 9 45 2 e IU TER 2 M 89 16 lt fe gt e 2 67177176 R Dimensional drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 10 Frame size R4 UL type 12 IP 55 5 re 0L 10 gt P 5 135 l 70 2 77 Bj In N qn o o e d o o o o o J 0181 Sly i i U l U i a 6761 067 S S i 8 a B lt 57707 viz o ie st Dimensional drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 136 Frame size R5 UL type 1 IP 21
7. AC S800 U1 type Frame size Input Fuse current A A V Manufacturer Type UL class Three phase supply voltage 525 V 575 V 600 V 0011 7 R4 10 20 600 Bussmann JJS 20 T 0016 7 R4 13 20 600 Bussmann JJS 20 T 0020 7 R4 19 30 600 Bussmann JJS 30 T 0025 7 R4 21 30 600 Bussmann JJS 30 T 0030 7 R4 29 45 600 Bussmann JJS 45 T 0040 7 R4 32 45 600 Bussmann JJS 45 T 0050 7 R5 45 70 600 Bussmann JJS 70 T 0060 7 R5 51 80 600 Bussmann JJS 80 T 0070 7 R6 70 100 600 Bussmann JJS 100 T 0100 7 R6 82 125 600 Bussmann JJS 125 a 0120 7 R6 103 150 600 Bussmann JJS 150 T 0145 7 R6 121 200 600 Bussmann JJS 200 T 0175 7 R6 150 200 600 Bussmann JJS 200 T 0205 7 R6 188 250 600 Bussmann JJS 250 T PDM code 00096931 J 00556489 Cable types Cable sizing is based on NEC Table 310 16 for copper wires 75 C 167 F wire insulation at 40 C 104 F ambient temperature Not more than three current carrying conductors in raceway or cable or earth directly buried For other conditions dimension the cables according to local safety regulations appropriate input voltage and the load current of the drive Copper cables with concentric copper shield Max load Cable type current A AWG MCM 18 14 22 12 31 10 44 8 57 6 75 4 88 3 101 2 114 1 132 1 0 154 2 0 176 3 0 202 410 224 250 MCM or 2 x 1 251 300 MCM or 2 x 1 0 PDM code 00096931 C Technic
8. 16170 ERES q 00000 lt 00000 Sc 9 99L G8 c El Qg H nas pa SIN LC 82 SIZ EN lt Ml o oo ki piel 5 Gol M S 3 Dimensional drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 137 Frame size R5 UL type 12 IP 55 E m Im N LN m FANE S G 5 ye NO o o ne Kol x ESAME d o o o o y E 1 ES Y 0127 209 y li A lt 3 8 S SZZ a 3 r st Dimensional drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 138 Frame size R6 UL type 1 IP 21 n 9972 007 R 6 vc R 1657 969 S 5 3 14 80 64739361 A Dimensional drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 139 Frame size R6 UL type 1 IP 21 0205 3 and 0255 5 units Note Only measurements that differ from those of the standard Frame size R6 UL type 1 IP 21 are given below
9. Connect the power cables Y Connect the control and the auxiliary control cables Y Check the installation Y Commission the drive Y Commission the optional brake chopper if present Product and service inquiries See Electrical installation Checking the insulation of the assembly Electrical installation Electrical installation Motor control and I O board RMIO and the optional module manual delivered with the module Installation checklist Appropriate firmware manual Resistor braking Address any inquiries about the product to your local ABB representative quoting the type code and serial number of the unit in question A listing of ABB sales support and service contacts can be found by navigating to ABB website and selecting Sales Support and Service network Product training For information on ABB product training navigate to ABB website and select Training courses Providing feedback on ABB Drives manuals Your comments on our manuals are welcome Go to ABB website and select Document Library Manuals feedback form LV AC arives About this manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 23 The ACS800 01 U1 What this chapter contains This chapter describes the operating principle and construction of the drive in short The ACS800 01 U1 The ACS800 01 U1 is a wall mountable drive f
10. Update Notice info clrwtr com 888 723 4773 Web www clrwtr com Ema 800 894 0412 Fax Phone and auxiliary circuits from the drive Therefore maintenance work on electrical parts of the drive or the motor can only be carried out after isolating the drive system from the main supply WARNING The Safe torque off function does not disconnect the voltage of the main Note The Safe torque off function can be used for stopping the drive in emergency stop situations In the normal operating mode use the Stop command instead If a running drive is stopped by using the function the drive will trip and stop by coasting If this is not acceptable e g causes danger the drive and machinery must be stopped using the appropriate stopping mode before using this function Note concerning permanent magnet motor drives in case of a multiple IGBT power semiconductor failure In spite of the activation of the Safe torque off function the drive system can produce an alignment torque which maximally rotates the motor shaft by 180 p degrees p denotes the pole pair number Note If you add or modify the wiring in the drive safety circuits ensure that the appropriate standards e g IEC 61800 5 1 EN 62061 EN ISO 13849 1 and 2 and the ABB guidelines are met After making the changes verify the operation of the safety function by testing it CHANGED page 62 63 Connecting the control cables Terminals Frame sizes R2 to R4 a
11. Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Guick guide for selecting between gG and aR fuses The table below is a short cut in selecting between gG and aR fuses The combinations cable size cable length transformer size and fuse type in the table fulfil the minimum requirements for the proper operation of the fuse 99 ACS800 01 size Cable type Supply transformer minimum apparent power Sy kVA Copper Aluminium Maximum cable length with gG Maximum cable length with aR fuses fuses 10m 50m 100 m 10m 100 m 200m Three phase supply voltage 208 V 220 V 230 V or 240 V 0025 2 3x25 Cu 3x35 Al 31 38 27 27 0030 2 3x35 Cu 3x50 AI 44 55 33 33 0040 2 3x50 Cu 3x70 Al 58 71 41 41 0050 2 3x70 Cu 3x95 AI 72 87 55 70 0060 2 3x95 Cu 3x120 AI 85 110 65 70 0070 2 3x120 Cu 3x185 AI 99 120 81 81 Three phase supply voltage 380 V 400 V or 415 V 0040 3 3x25 Cu 3x35 Al 54 57 71 48 48 48 0050 3 3x35 Cu 3x50 AI 76 82 110 58 58 58 0060 3 3x50 Cu 3x70 Al 100 110 140 70 70 70 0075 3 3x70 Cu 3x95 Al 130 140 160 99 99 140 0070 3 3x70 Cu 3x95 Al 130 140 160 96 96 140 0100 3 3x95 Cu 3x120 AI 150 160 190 120 120 140 0120 3 3x120 Cu 3x185 AI 170 190 210 140 140 140 0135 3 3x150 Cu 3x240 AI 200 220 250 160 160 160
12. motor Nmotor fewp frequency at field weakening point Uymains mains input power voltage Unmotor rated motor voltage fNmotor rated motor frequency 0 01 Hz See section EC data 1 5 Pha 1 1 Py Or Peontmax whichever value is greatest 8 to 300 Hz 3 kHz average In 690 V units 2 kHz average Sizing method Max motor cable length Scalar control DTC control according to by and long R2 to R3 100 m 328 ft R2 150 m 492 ft according to Icontmax at ambient temperatures below 30 C 86 F R4 to R6 300 m 984 ft R3 to R6 300 m 984 ft according to cont max at ambient temperatures above 30 C 86 F R2 50 m 164 ft Note This applies to units with EMC filter also R3 and R4 100 m 328 ft R5 and R6 150 m 492 ft Note With cables longer than 100 m 328 ft the EMC Directive requirements may not be fulfilled See section CE marking Approximately 98 at nominal power level Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 108 Cooling Method Free space around the unit Internal fan flow direction from bottom to top See chapter Mechanical installation Degrees of protection IP 21 UL type 1 and IP 55 UL type 12 Without connection box and front cover the unit must be protected against contact according to IP 2x see chapter Electrical installation Cabinet installation IP 21
13. 2 ei ga a Wy GT o at eae dae a ON A WE YDY Fy 9 Op ratioNn s ne uu O NA M od gr Seite O oat i Set se 10 Permanent magnet motor YY FI FR EL R R hh 11 Installation and maintenance work 11 Start Up and operation tun 9 cepe MA E ce e OF rd FY eni en ee Ad ne 11 Table of contents About this manual What this chapter contains ue un eh Rise ordre Lee ni 19 Intended audieriCe ua ere ote et PW AAA ese HI OU eR dts 19 Common chapters for several products oococccocccoc 19 Categorization according to the frame size YYYYY Y FFF FFF esee 19 Categorization according to the code 19 Contents i zi min lano bala pl lk 20 Installation and commissioning flowchart see 21 Product and service inquiries lille ue 22 Product traininig 2 na ERES teu Re ea PS Ies NO ENS 22 Providing feedback on ABB Drives manuals else 22 The ACS800 01 U1 What this chapter Contains iia pra a Rx Pep e DO O WYN ES 23 The ACS800 0T UT i erm mer sA Rang Weeks r KE t ctm ihi i rag E RR RR ls 23 TVpe code oeu A IND ae eret COP IO Dens 24 Main circuit ad Control se lia an ederent e p RR A CE RU EXE runy 25 Diagram xe Ere INCERTIS ML ie ORE e IE d ade De P A NIWY 25 Operation ic do E UELLE z b AA EAN EE 25 Printed cireuit DOards aeo grt entr A trio a an 26 Motor Controls uso erroe er tT UN a n Ee dA a e bes 26 Mechanical installation Uripacking the unity cl ic ALT wh YNA ON DEP Ree rra 27
14. 0120 7 112 1940 125 126000 690 ABB Control OFAA1GG125 1 0145 7 131 2400 160 220000 690 ABB Control OFAA1GG160 1 0175 7 162 2850 200 350000 690 ABB Control OFAA1GG200 1 0205 7 186 3820 250 700000 690 ABB Control OFAA2GG250 2 Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 97 Standard gG fuses AC 5800 01 size Input Min Fuse current short circuit current A A A S V Manufacturer Type IEC size maximum total Ft value for 550 V or 690 V 1 minimum short circuit current of the installation Note 1 See also Planning the electrical installation Thermal overload and short circuit protection For UL recognized fuses see NEMA data on page 102 Note 2 In multicable installations install only one fuse per phase not one fuse per conductor Note 3 Larger fuses than the recommended ones must not be used Note 4 Fuses from other manufacturers can be used if they meet the ratings and the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table PDM code 00096931 J 00556489 Ultrarapid aR fuses ACS800 01 size Input Min Fuse current short circuit current 1 A A A s V Manufacturer Type IEC size Three phase supply voltage 208 V 220 V 230 V or 240 V 0025 2 67 400 100 4650 690
15. I I I SAFE TORQUE OFF BOARD i I 1 1 1 24V 1 XI 2 ww xxi d PE I ov X1 2 8 Z p uoc X2 2 1 44 2 24 V X1 3 v2 vur xz3 1 X41 4 l ov x1 4 love PWRFAL X2 4 Tuan 3 T ze A gt 1 1 1 I 1 1 ENS I i i I PWR OK GREEN BH V48 I I l 1 1 1 1 1 1 1 1 1 i 1 1 I 1 I 1 1 HEDD NEN IA ee APRA Dimensions 3AUA0000069101 The dimensions of the ASTO board are the same as the dimensions of the AGPS board See Dimensional drawing on page 70 Update Notice Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ASTO 11C board specifications Nominal input voltage 24 V DC Nominal input current 40 mA 20mA per channel X1 terminal sizes 4x 2 5 mm Nominal output current 0 4A X2 terminal block type JST B4P VH Ambient temperature 0 50 C Relative humidity Max 90 no condensation allowed Dimensions with 167 x 128 x 52 mm Height x Weight x Depth enclosure Weight with enclosure 0 75 kg NEW page 108 Ambient condi Modules with option Q967 the installation site altitude in operation is 0 to 2000 m ions Operation installed for stationary use Installation site altitude Modules with option Q967 0 to 2000 m Update Notice Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Safety instructions What this chapter contains This
16. Note The installation must always be designed and made according to applicable local laws and regulations ABB does not assume any liability whatsoever for any installation which breaches the local laws and or other regulations Furthermore if the recommendations given by ABB are not followed the drive may experience problems that the warranty does not cover Motor selection and compatibility 1 Select the motor according to the rating tables in chapter Technical Data Use the DriveSize PC tool if the default load cycles are not applicable 2 Check that the motor ratings lie within the allowed ranges of the drive control program motor nominal voltage is 1 2 2 Uy of the drive e motor nominal current is 1 6 2 long of the drive in DTC control and 0 2 long in scalar control The control mode is selected by a drive parameter 3 Check that the motor voltage rating meets the application requirements Resistor braking Motor voltage rating no resistor braking is in use Un frequent or long term brake cycles will be used UAceq1 UN rated input voltage of the drive Unceqt Ubc 1 35 Uaceg is the equivalent AC power source voltage of the drive in V AC Upc is the maximum DC link voltage of the drive in V DC For resistor braking Upc 1 21 x nominal DC link voltage For units with IGBT supply See the parameter value Note Nominal DC link voltage is Uy x 1 35 or Uy x 1 41 in V DC See n
17. Table of contents Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 14 Delivety check senos restate wet thet oh A A ep t ees 28 Beforerinstallation eie ee triente eee R CR en nre pl ge Re GW Un YR CR E 28 Requirements for the installation site llli 28 Wall edet ox REFERRI del qa P YAR eR 28 ld c PR 28 Free space around the unit eee 29 Mounting the drive on the wall RR un 30 Units without vibration dampers Re 30 IP 55 UL type 12 marine applications C132 of frame sizes RA to R6 30 Units with vibration dampers FC131 0 0 0 0 0c ne 30 UETZ Unlts aes a errata ad rte Ran ieu edo edits e AR 30 Cabinet installation RE EIER Sik Crea Puteo PE TRANCE A E ER 31 Preventing cooling air recirculation YVYFF IA 31 Unit above anotligr oe PA eed bes e Dev GAR DAS 32 Planning the electrical installation What this chapter contains aure Y Y Eque e ERE DER Db t 33 Motor selection and compatibility VVYF FFF EF ER FF RR ua 33 Protecting the motor insulation and bearings FFI Fu 34 Reguirements tabl amp AA Hu GW YA DDI DE Re ka ka A 35 Permanent magnet synchronous motor FY FF FF FF FF FR Y a 38 Supply Connection ia rep deer xe nere et yd YW A Y MI A 39 Disconnecting device disconnecting means esse 39 EUG eS re OO ot NO SDN S det C HD YO UE SUAE 39 US Lusso Gaede
18. UL type 1 Ambient conditions Environmental limits for the drive are given below The drive is to be used in a heated indoor controlled environment Operation installed for stationary use Storage in the protective package Transportation in the protective package Installation site altitude 0 to 4000 m 13123 ft above sea level above 1000 m 3281 ft see section Derating Air temperature 15 to 50 C 5 to 122 F 40 to 70 C 40 to 40 to 70 C 40 to No frost allowed See section 158 F 158 F Derating Relative humidity 5 to 95 Max 95 Max 95 No condensation allowed Maximum allowed relative humidi corrosive gases y is 60 in the presence of Contamination levels IEC 60721 3 3 IEC 60721 3 2 IEC 60721 3 1 No conductive dust allowed Boards without coating Chemical gases Class 3C1 Solid particles Class 3S2 Boards with coating Chemical gases Class 3C2 Solid particles Class 3S2 Boards without coating Chemical gases Class 1C2 Solid particles Class 183 Boards with coating Chemical gases Class 1C2 Solid particles Class 183 Boards without coating Chemical gases Class 2C2 Solid particles Class 252 Boards with coating Chemical gases Class 2C2 Solid particles Class 252 Atmospheric pressure 70 to 106 kPa 0 7 to 1 05 atmospheres 70 to 106 kPa 0 7 to 1 05 atmospheres 60 to 106 kPa 0 6 to 1 05 atmospher
19. bo uc PA a la 4 18 0047 jsa lan jow V Wc Jal la Y OVAOEZ SLI Installation of AGPS board Prevention of Unexpected Start Q950 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 70 Dimensional drawing The dimensional drawing of the AGPS board is shown below MOI 3AFE68293898 Installation of AGPS board Prevention of Unexpected Start Q950 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 71 AGPS 11C board specifications Nominal input voltage 115 230 V AC 10 Nominal input current 0 1 A 230 V 0 2A 115 V Nominal frequency 50 60 Hz Max external fuse 16A X1 terminal sizes 3x2 5 mm Output voltage 15V DC 20 5 V Nominal output current 0 4A X2 terminal block type JST B4P VH Ambient temperature 0 50 C Relative humidity Max 90 no condensation allowed Dimensions with enclosure 167 x 128 x 52 mm height x width x depth Weight with enclosure 0 75 kg Approvals C UL US listed Installation of AGPS board Prevention of Unexpected Start Q950 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 72 Installation of AGPS board Preven
20. lt 100 kW Apply the requirements of range Py gt 350 kW to motors within the range 100 kW lt Py lt 350 kW In other cases consult the motor manufacturer S Motor type Nominal mains Reguirement for E voltage AC line Motor insulation ABB duldt filter insulated N end bearing and ABB common mode voltage system filter Py lt 55 kW 55 kW lt Py lt 200 kW Py gt 200 kW Py lt 74 HP 74 HP lt Py lt 268 HP Py gt 268 HP A Random Un lt 500 V Standard N N CMF B wound M3AA 590 y lt Uy lt 600 V Standard du dt du dt N du dt N CMF B M3AP M3BP or Reinforced N N CMF 600 V lt Uy lt 690 V Reinforced du dt du dt N du dt N CMF Note 4 HXR and AMA motors AII AMA machines manufactured in Helsinki for drive systems have form wound windings All HXR machines manufactured in Helsinki starting 1 1 1998 have form wound windings Note 5 ABB motors of types other than M2 M3 HX_ and AM_ Use the selection criteria given for non ABB motors Note 6 Resistor braking of the drive When the drive is in braking mode for a large part of its operation time the intermediate circuit DC voltage of the drive increases the effect being similar to increasing the supply voltage by up to 20 percent The voltage increase should be taken into consideration when determining the motor insulation requirement Example Motor insulation requirement for a 400 V application must be selected as if the dr
21. off The relay contacts on the RMIO board are protected with varistors 250 V against overvoltage peaks In spite of this it is highly recommended to equip inductive loads with noise attenuating circuits varistors RC filters AC or diodes DC in order to minimize the EMC emission at switch off If not suppressed the disturbances may connect capacitively or inductively to other conductors in the control cable and form a risk of malfunction in other parts of the system Install the protective component as close to the inductive load as possible Do not install protective components at the RMIO board terminal block RMIO Relay outputs Varistor x25 1 RO1 o 230 VAC 2 801 o 3 RO1 RC filter X26 MH sa 1 RO2 o 230 VAC 2 ROZ 3 RO2 Diode x27 11 1 RO3 T 2 RO3 24 V DC ee 3 RO3 Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 48 Selecting the control cables All control cables must be shielded Use a double shielded twisted pair cable Figure a e g JAMAK by NK Cables Finland for analogue signals This type of cable is recommended for the pulse encoder signals also Employ one individually shielded pair for each signal Do not use common return for different analogue signals A double shielded cable is
22. 0165 3 3x185 Cu 3x240 AI 240 260 310 180 180 200 0205 3 3x240 Cu 2x 3x95 AI 232 257 310 134 153 196 Three phase supply voltage 380 V 400 V 415 V 440 V 460 V 480 V or 500 V 0050 5 3x25 Cu 3x35 Al 67 70 79 56 56 56 0060 5 3x25 Cu 3x50 AI 95 110 130 68 68 68 0070 5 3x35 Cu 3x70 Al 130 140 160 83 83 83 0105 5 3x70 Cu 3x95 Al 160 170 190 130 130 150 0100 5 3x70 Cu 3x95 Al 160 170 190 110 120 150 0120 5 3x95 Cu 3x120 Al 190 200 220 140 140 150 0140 5 3x95 Cu 3x150 Al 190 200 220 160 160 160 0165 5 3x150 Cu 3x240 Al 250 260 290 200 200 200 0205 5 3x185 Cu 3x240 Al 290 320 360 230 230 230 0255 5 3x240 Cu 2x 3x95 Al 289 312 355 167 185 218 Three phase supply voltage 525 V 550 V 575 V 600 V 660 V or 690 V 0050 7 3x16 Cu 3x25 Al 65 67 70 63 63 63 0060 7 3x16 Cu 3x25 Al 70 70 70 70 70 70 0070 7 3x25 Cu 3x50 Al 95 95 99 95 95 95 0100 7 3x35 Cu 3x50 Al 130 140 150 110 110 110 0120 7 3x50 Cu 3x70 Al 180 180 190 140 140 140 0145 7 3x70 Cu 3x95 Al 220 220 240 160 160 160 0175 7 3x95 Cu 3x120 Al 260 260 280 200 200 200 0205 7 3x95 Cu 3x150 Al 340 360 390 230 230 230 Note 1 The supply transformer minimum power in kVA is calculated with a z value of 6 and frequency 50 Hz Note 2 The table is not intended for transformer selection that must be done separately Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 100 The following parameters may effect on correct th
23. 125 Frame size R6 IP 21 UL type 1 126 Frame size R6 IP 21 UL type 1 205 3 and 255 5 units sss 127 Frame size R6 IP 55 UL type 12 128 Dimensional drawings USA eet uu au 129 Frame size R2 UL type 1 IP 21 130 Frame size R2 UL type 12 IP BB Y FF uu 131 Frame size R3 UL type 1 IP 21 132 Frame size R3 UL type 12 IP 55 133 Frame size R4 UL type 1 IP 21 134 Frame size R4 UL type 12 IP BB FF FF FR RF aaa ai 135 Frame size R5 UL type 1 IP 21 136 Frame size R5 UL type 12 IP 55Y ueu semine DAD ND DRDD RII AE 137 Frame size R6 UL type 1 IP 21 138 Frame size R6 UL type 1 IP 21 0205 3 and 0255 5 units o 139 Frame size R6 UL type 12 IP BB IF FF FF RR Fu uu 140 Resistor braking What this chapter contains 0 0 02020 hr 141 Availability of brake choppers and resistors for the ACS800 141 Selecting the correct drive chopper resistor combination YYY YY a 141 Optional brake chopper and resistor s for the ACS800 01 U1 VFYY uu 142 Resistor installation and Wiring FF EF RR II 144 Protection of frame sizes R2 to R5 ACS800 01 U1 145 Protection of frame size R6 9 FF EF EF ER EE EF Y Y Y Y og 145 Brake circuit commissioning YY I FFR FL FFF Rh 146 External 24 V power supply for the RMIO board via terminal X34 What this chapter contains YY FE
24. 154 60 R6 238 4910 Three phase supply voltage 380 V 400 V 415 V 440 V 460 V or 480 V 0004 5 6 5 4 9 3 3 4 2 R2 21 410 0005 5 8 2 6 2 3 4 2 2 R2 21 480 0006 5 10 8 8 1 5 5 6 3 R2 21 550 0009 5 13 8 11 7 5 8 1 5 R2 21 690 0011 5 17 6 14 10 11 7 5 R2 21 860 0016 5 24 21 15 15 10 R3 41 1150 0020 5 32 27 20 21 15 R3 41 1490 0025 5 46 34 25 27 20 R3 41 1790 0030 5 62 42 30 34 25 R4 61 2090 0040 5 72 52 40 37 30 R4 61 2770 0050 5 86 65 50 52 40 R5 147 3370 0060 5 112 79 60 65 50 R5 147 4050 0070 5 138 96 75 77 60 R5 147 4910 0105 5 170 141 100 100 75 R5 238 7340 0100 5 164 124 100 96 75 R6 238 6610 0120 5 202 157 125 124 100 R6 238 7890 0140 5 282 180 150 156 125 R6 238 9600 0205 5 326 245 200 215 150 R6 238 12980 Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 103 AC S800 U1 size max Normal use Heavy duty use Frame Air flow Heat size dissipation bon PN Iona Prd A A HP A HP ft3 min BTU Hr Three phase supply voltage 525 V 575 V 600 V 0011 7 14 11 5 10 8 5 7 5 R4 61 1050 0016 7 19 15 10 11 10 R4 61 1200 0020 7 28 20 15 20 15 T5 R4 61 1550 0025 7 38 23 20 20 20 R4 61 1850 0030 7 44 30 25 30 25 25 R4 61 2100 0040 7 54 34 30 30 30 R4 61 2400 0050 7 68 46 40 40 40 R5 147 2900 0060 7 84 52 50 42 40 R5 147 3450 0070 7 104 73 60 54 50 R6 238 4200 0100 7 1
25. 2929 M 7 717 24VD 24 V DC max 100 mA open 1 closed 8 L g 24VD DI4 Ramp times according to 9 L Ta DGND1 Digital ground 0 parameters 22 02 and 22 03 10 5 1 DGND2 Digital ground ESU T 11 1 11 DIL Start interlock 0 stop 9 See par group 12 CONSTANT X23 X23 SPEEDS 1 Si 24V Auxiliary voltage output and input non DIS DIG Operation 2 1 15 GND isolated 24 V DC 250 mA 5 o 0 Setspeed through Al1 x25 x25 1 0 Constant speed 1 1 RAT RO1 Relay output 1 ready O 1 Constant speed 2 2 12 RO1 1 1 Constant speed 3 3 F 13 RO1 X26 X26 4 See parameter 21 09 START INTRL 1 11 RO2 Relay output 2 running FUNC 5 Total maximum current shared 2 gt gt between this output and optional r 3 13 ROZ modules installed on the board X27 X27 R 1 zu RO3 Relay output 3 fault 1 Fault 2 712 RO3 3 713 RO3 Motor control and O board RMIO Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 76 RMIO board specifications Analogue inputs Insulation test voltage Max common mode voltage between the channels Common mode rejection ratio Resolution Inaccuracy Constant voltage output With Standard Control Program two programmable differential current inputs 0 mA 4 mA 20 mA Rin 100 ohm and one programmable differential voltage input 10V 0V 2V 10 V Rin 200 kohm The analogue inputs are galvanically isolated as
26. 8 176 766 GEU LEE Z lt Gyl 19 Supplementary page 3AUA0000057717 2009 04 16 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 141 Resistor braking What this chapter contains This chapter describes how to select protect and wire brake choppers and resistors The chapter also contains the technical data Availability of brake choppers and resistors for the ACS800 Frame R2 and R3 drives and 690 V units of frame size R4 have a built in brake chopper as standard equipment For other units brake choppers are optionally available as built in units indicated in the type code by D150 Resistors are available as add on kits Selecting the correct drive chopper resistor combination 1 Calculate the maximum power Pmax generated by the motor during braking 2 Select a suitable drive brake chopper brake resistor combination for the application according to the following tables take account of other factors in the drive selection also The following condition must be met Por Z Pmax where Por denotes Prs Pbr10 Pbr30 Porso Or Pbrcont depending on the duty cycle 3 Check the resistor selection The energy generated by the motor during a 400 second period must not exceed the resistor heat dissipation capacity Ep If the Ep value is not sufficient it is possible to use a four resistor assembly in which two standard resistors are connected in parallel two in s
27. AGPS board Prevention of Unexpected Start Q950 contains electrical installation instructions of the optional Prevention of Unexpected Start function Q950 of the drive and specifications of the board Motor control and I O board RMIO shows the external control connections to the I O board Installation checklist contains a list for checking the mechanical and electrical installation of the drive Maintenance contains preventive maintenance instructions Technical data contains the technical specifications of the drive e g the ratings sizes and technical requirements provisions for fulfilling the requirements for CE and other markings and warranty policy Dimensional drawings contains the dimensional drawings of the drive Resistor braking describes how to select protect and wire brake choppers and resistors The chapter also contains the technical data External 24 V power supply for the RMIO board via terminal X34 describes how to connect an external 24 V power supply for the RMIO board using terminal X34 About this manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Installation and commissioning flowchart Task Identify the frame size of your drive R2 R3 R4 R5 or R6 Plan the installation Check the ambient conditions ratings required cooling air flow input power connection compatibility of the motor motor connection and other technical da
28. Braking power Brake resistor s ACS800 U1 type of the chopper and the drive Pprcont Type R ER PRcont kW ohm KJ kW 230 V units 0001 2 0 55 SACE08RE44 44 210 1 0002 2 0 8 SACE08RE44 44 210 1 0003 2 1 1 SACE08RE44 44 210 1 0004 2 1 5 SACE08RE44 44 210 1 0005 2 2 2 SACE15RE22 22 420 2 0006 2 3 0 SACE15RE22 22 420 2 0009 2 4 0 SACE15RE22 22 420 2 0011 2 5 5 SACE15RE13 13 435 2 0016 2 11 SAFUR90F575 8 1800 4 5 0020 2 17 SAFUR90F575 8 1800 4 5 0025 2 23 SAFUR80F500 6 2400 6 0030 2 28 SAFUR125F500 4 3600 9 0040 2 33 SAFUR125F500 4 3600 9 0050 2 45 2xSAFUR125F500 2 7200 18 0060 2 56 2xSAFUR125F500 2 7200 18 0070 2 68 2xSAFUR125F500 2 7200 18 Resistor braking Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 143 AC 5800 01 type Braking power Brake resistor s ACS800 U1 type Of the chopper and the drive Porcont Type R ER PRcont kW ohm kJ kW 400 V units 0003 3 1 1 SACE08RE44 44 210 1 0004 3 1 5 SACE08RE44 44 210 1 0005 3 2 2 SACEOBRE44 44 210 1 0006 3 3 0 SACE08RE44 44 210 1 0009 3 4 0 SACEOBRE44 44 210 1 0011 3 5 5 SACE15RE22 22 420 2 0016 3 7 5 SACE15RE22 22 420 2 0020 3 11 SACE15RE22 22 420 2 0025 3 23 SACE15RE13 13 435 2 0030 3 28 SACE15RE13 13 435 2 0040 3 33 SAFUR90F575 8 1
29. R6 405 2310 0140 5 180 282 110 163 110 141 90 R6 405 2810 0165 5 225 326 132 220 132 163 110 R6 405 3260 0205 5 260 326 160 254 160 215 132 R6 405 3800 0255 5 290 351 200 285 200 234 160 R6 405 4500 Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 91 Nominal ratings Icont max Imax temperature Typical ratings No overload us P cont max typical mo e 230 V 400 V 500 V or 690 V Light overload use 10 overload capability lon PN typical mo 230 V 400 V 500 V or 690V Heavy duty use 50 overload capability land Phd typical mo 230 V 400 V 500 V or 690 V Sizing continuous rms output current No overload capability at 40 C maximum output current Available for 10 s at start otherwise as long as allowed by drive or power The power ratings apply to most IEC 34 motors a continuous rms current 10 overload is allowed for one minute every 5 minutes or power The power ratings apply to most IEC 34 motors a continuous rms current 50 overload is allowed for one minute every 5 minutes or power The power ratings apply to most IEC 34 motors a ACS800 01 size Nominal No Light overload Heavy duty use Frame Air flow Heat ratings canad use size dissipation Icontmax Imax Peont max lon PN Iona P
30. V 0011 7 12 16 1100 690 ABB Control OFAA000GG16 000 0016 7 15 20 2430 690 ABB Control OFAA000GG20 000 0020 7 21 25 4000 690 ABB Control OFAA000GG25 000 0025 7 24 32 7000 690 ABB Control OFAA000GG32 000 0030 7 33 35 11400 690 ABB Control OFAA000GG35 000 0040 7 35 50 22800 690 ABB Control OFAA000GG50 000 PDM code 00096931 J Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 94 Frame sizes R5 and R6 Choose between gG and aR fuses according to the table under Quick guide for selecting between gG and aR fuses on page 99 or verify the operating time by checking that the short circuit current of the installation is at least the value given in the fuse table The short circuit current can be calculated as follows U lk2 ph 2 2 2 R Z Xp where lk2 pn Short circuit current in symmetrical two phase short circuit U network line to line voltage U R cable resistance ohm Zk zk Un Sp transformer impedance ohm zk transformer impedance 96 Uy transformer rated voltage V Sy nominal apparent power of the transformer kVA X cable reactance ohm Calculation example Drive ACS800 01 0075 3 supply voltage Transformer rated power Sy 600 kVA rated voltage drive supply voltage Uy 430 V transformer impedance z 7 2 Supply cable length 170m resistance length 0 398 ohm km reactance le
31. certain frame sizes are marked with the symbol of the frame size R2 R3 or R8 The frame size is not marked on the drive designation label To identify the frame size of your drive see the rating tables in chapter Technical data The ACS800 01 U1 is manufactured in frame sizes R2 to R6 Categorization according to the code The instructions technical data and dimensional drawings which concern only certain optional selections are marked with codes e g E202 The options included in the drive can be identified from the codes visible on the type designation label of the drive The code selections are listed in chapter The ACS800 01 U1 under Type code About this manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 20 Contents The chapters of this manual are briefly described below Safety instructions give safety instructions for the installation commissioning operation and maintenance of the drive About this manual lists the steps in checking the delivery and installing and commissioning the drive and refers to chapters sections in this manual and other manuals for particular tasks The ACS800 01 U1 describes the drive Mechanical installation instructs how to place and mount the drive Planning the electrical installation instructs on the motor and cable selection protections and cable routing Electrical installation shows how to wire the drive Installation of
32. end of the shield unconnected or ground it indirectly via a few nanofarads high frequency capacitor e g 3 3 nF 630 V The shield can also be grounded directly at both ends if they are in the same ground line with no significant voltage drop between the end points Keep the signal wire pairs twisted as close to the terminals as possible Twisting the wire with its return wire reduces disturbances caused by inductive coupling Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 65 Cabling of I O and fieldbus modules Module As short as possible d 0 0 L 0 Note The RDIO module does not 9 7TT include a terminal for cable shield 9 grounding Ground the pair cable shields here As short as possible Note1 If the encoder is of unisolated type ground the encoder cable at the drive end only If the encoder is galvanically isolated from the motor shaft and the stator frame ground the encoder cable shield at the drive and the encoder end IE Note 2 Twist the pair cable wires Wrap copper tape around the stripped part of the cable under the clamp Be careful Do not cut the grounding wire Clamp as close to the terminals as possible Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info c
33. fuse is below 0 5 seconds The operating time depends on the supply network impedance and the cross sectional area and length of the supply cable The short circuit current can be calculated as shown below in section Frame sizes R5 and R6 Note 1 See also Planning the electrical installation Thermal overload and short circuit protection For UL recognized fuses see NEMA data on page 102 Note 2 In multicable installations install only one fuse per phase not one fuse per conductor Note 3 Larger fuses than the recommended ones must not be used Note 4 Fuses from other manufacturers can be used if they meet the ratings and the melting curve of he fuse does not exceed the melting curve of the fuse mentioned in the table ACS800 01 Input Fuse size current A AZs V Manufacturer Type IEC size Three phase supply voltage 208 V 220 V 230 V or 240 V 0001 2 44 10 483 500 ABB Control OFAF000H10 000 0002 2 5 2 10 483 500 ABB Control OFAF000H10 000 0003 2 6 7 10 483 500 ABB Control OFAF000H10 000 0004 2 9 3 16 993 500 ABB Control OFAF000H16 000 0005 2 12 16 993 500 ABB Control OFAF000H16 000 0006 2 16 20 1620 500 ABB Control OFAF000H20 000 0009 2 23 25 3100 500 ABB Control OFAF000H25 000 0011 2 31 40 9140 500 ABB Control OFAF000H40 000 0016 2 40 50 15400 500 ABB Control OFAF000H50 000 0020 2 51 63 21300 500 ABB Control OFAF000H63 000 Technical data Phone 800
34. is lt 50 of the conductivity of the phase conductor and there is no symmetrically constructed grounding conductor in the cable see Planning the electrical installation Selecting the power cables Note If there is a symmetrically constructed grounding conductor in the motor cable in addition to the conductive shield connect the grounding conductor to the grounding terminal at the drive and motor ends Do not use an asymmetrically constructed motor cable for motors 30 kW 40 HP Connecting its fourth conductor at the motor end increases bearing currents and causes extra wear Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 54 Conductor stripping lengths Strip the conductor ends as follows to fit them inside the power cable connection terminals Frame size Stripping length mm in R2 R3 10 0 39 R4 R5 16 0 63 R6 28 1 10 Allowed wire sizes tightening torques See Technical data Cable entries Wall installed units European version Power cable installation procedure 1 Remove the front cover in frame size R6 the lower front cover by releasing the retaining clip with a screw driver and lifting the cover from the bottom outwards For IP 55 units see Mechanical installation Mounting the drive on the wall 2 Slide the back plate of the connection box to the holes below the drive 3 Fasten the
35. is not needed with AC drives However if a drive is to be connected in a system with compensation capacitors installed note the following restrictions filters to the motor cables between the drive and the motor They are not meant to be used with AC drives and can cause permanent damage to the drive or themselves WARNING Do not connect power factor compensation capacitors or harmonic Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 46 If there are power factor compensation capacitors in parallel with the three phase input of the drive 1 Do not connect a high power capacitor to the power line while the drive is connected The connection will cause voltage transients that may trip or even damage the drive 2 If capacitor load is increased decreased step by step when the AC drive is connected to the power line Ensure that the connection steps are low enough not to cause voltage transients that would trip the drive 3 Check that the power factor compensation unit is suitable for use in systems with AC drives i e harmonic generating loads In such systems the compensation unit should typically be equipped with a blocking reactor or harmonic filter Equipment connected to the motor cable Installation of safety switches contactors connection boxes etc To minimize the emission level when safety switches contactors connection boxes
36. lh uu 147 Parameter Settings eii dea di o Pa 147 Connecting 24 V external power supply Y Y eee cette eee eee 148 Table of contents Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 19 About this manual What this chapter contains This chapter describes the intended audience and contents of this manual It contains a flowchart of steps in checking the delivery installing and commissioning the drive The flowchart refers to chapters sections in this manual and other manuals Intended audience This manual is intended for people who plan the installation install commission use and service the drive Read the manual before working on the drive The reader is expected to know the fundamentals of electricity wiring electrical components and electrical schematic symbols This manual is written for readers worldwide Both SI and imperial units are shown Special US instructions for installations within the United States that must be installed per the National Electrical Code and local codes are marked with US Common chapters for several products Chapters Safety instructions Planning the electrical installation Motor control and I O board RMIO and Resistor braking apply to several ACS800 products which are listed at the beginning of the chapters Categorization according to the frame size Some instructions technical data and dimensional drawings which concern only
37. long motor cables increase the ground leakage current and may cause fault current circuit breakers to function Prevention of Unexpected Start The drive can be eguipped with an optional Prevention of Unexpected Start function according to standards IEC EN 60204 1 1997 ISO DIS 14118 2000 and EN 1037 1996 The Prevention of Unexpected Start function disables the control voltage of the power semiconductors thus preventing the inverter from generating the AC voltage required to rotate the motor By using this function short time operations like cleaning and or maintenance work on non electrical parts of the machinery can be performed without switching off the AC power supply to the drive The operator activates the Prevention of Unexpected Start function by opening a Switch on a control desk An indicating lamp on the control desk will light signalling that the prevention is active The switch can be locked out The user must install on a control desk near the machinery switching disconnecting device for the circuitry Means shall be provided to prevent inadvertent and or mistaken closure of the disconnecting device EN 60204 1 1997 indicating lamp on starting the drive is prevented off drive is operative safety relay type BD5935 has been approved by ABB For connections to the drive see chapter nstallation of AGPS board Prevention of Unexpedted Start Q950 WARNING The Prevention of Unexpected Start f
38. min after disconnecting mains power Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 92 Checking the insulation of the assembly Drive Every drive has been tested for insulation between the main circuit and the chassis 2500 V rms 50 Hz for 1 second at the factory Therefore do not make any voltage tolerance or insulation resistance tests e g hi pot or megger on any part of the drive Input cable Check the insulation of the input cable according to local regulations before connecting it to the drive Motor and motor cable Check the insulation of the motor and motor cable as follows 1 Check that the motor cable is disconnected from the drive output terminals U2 V2 and W2 m 2 Measure the insulation resistances of the motor cable and the motor between each phase and the Protective Earth by using a measuring voltage of 1 kV DC The insulation resistance must be higher than 1 Mohm PE IT ungrounded systems Disconnect the EMC filter capacitors of selections E202 and E200 before connecting the drive to an ungrounded system For detailed instructions on how to do this please contact your local ABB distributor system an ungrounded power system or a high resistance grounded over 30 ohms power system the system will be connected to earth potential through the EMC filter capacitors of the drive This may cause danger or damage the
39. of the drive a m s m LUTA ang OO 1 UU at tU DOK i Motor control and gt gt Optional module 1 RMBA RAIO RDIO RDNA RLON RIBA RPBA I O board RMIO RCAN RCNA RMBP RETA RRIA or RTAC External control via eee module 2 RTAC RAIO RRIA analogue digital inputs and outputs a 0 lt gt DDCS communication option module 3 RDCO 01 RDCO 02 or RDCO 03 Input power ale Output power ae J Brake chopper in frame sizes R2 and R3 A and in 690 V units of frame size R4 L 4 optional in other frame sizes R UDC UDC R Operation This table describes the operation of the main circuit in short Component Description six pulse rectifier converts the three phase AC voltage to DC voltage capacitor bank energy storage which stabilizes the intermediate circuit DC voltage IGBT inverter converts the DC voltage to AC voltage and vice versa The motor operation is controlled by switching the IGBTs The ACS800 01 U1 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 26 Printed circuit boards The drive contains the following printed circuit boards as standard main circuit board RINT motor control and I O board RMIO EMC filter board RRFC when EMC equipment is selected or varistor board RVAR otherwise control panel CDP 312R Motor control The motor control is based on the D
40. recycled The plastic parts can either be recycled or burned under controlled circumstances according to local regulations Most recyclable parts are marked with recycling marks If recycling is not feasible all parts excluding electrolytic capacitors and printed circuit boards can be landfilled The DC capacitors C1 1 to C1 x contain electrolyte and the printed circuit boards contain lead both of which are classified as hazardous waste within the EU They must be removed and handled according to local regulations For further information on environmental aspects and more detailed recycling instructions please contact your local ABB distributor Applicable standards EN 60204 1 2006 EN 60529 1991 IEC 60529 EC 60664 1 2007 EN 61800 3 2004 EN 61800 5 1 2003 UL 508C 2002 NEMA 250 2003 CSA C22 2 No 14 05 2005 The drive complies with the following standards The compliance with the European Low Voltage Directive is verified according to standards EN 61800 5 1 and EN 60204 1 Safety of machinery Electrical eguipment of machines Part 1 General reguirements Provisions for compliance The final assembler of the machine is responsible for installing an emergency stop device a supply disconnecting device Degrees of protection provided by enclosures IP code Insulation coordination for equipment within low voltage systems Part 1 Principles requirements and tests Adjustable
41. skills in installing and or commissioning power drive systems including their EMC aspects Drive of category C3 drive of rated voltage less than 1000 V and intended for use in the second environment and not intended for use in the first environment Drive of category C4 drive of rated voltage equal to or above 1000 V or rated current equal to or above 400 A or intended for use in complex systems in the second environment Compliance with the EMC Directive The EMC Directive defines the requirements for immunity and emissions of electrical equipment used within the European Union The EMC product standard EN 61800 3 2004 covers requirements stated for drives Compliance with the EN 61800 3 2004 First environment drive of category C2 The drive complies with the standard with the following provisions 1 The drive is equipped with EMC filter E202 2 The motor and control cables are selected as specified in the Hardware Manual 3 The drive is installed according to the instructions given in the Hardware Manual 4 Maximum cable length is 100 metres WARNING The drive may cause radio interference if used in a residential or domestic environment The user is required to take measures to prevent interference in addition to the requirements for CE compliance listed above if necessary Note It is not allowed to install a drive equipped with EMC filter E202 on IT unearthed systems The supply network becomes connected to e
42. speed electrical power drive systems Part 3 EMC requirements and specific test methods Adjustable speed electrical power drive systems Part 5 1 Safety requirements electrical thermal and energy UL Standard for Safety Power Conversion Equipment second edition Enclosures for Electrical Equipment 1000 Volts Maximum Industrial control equipment Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 110 CE marking A CE mark is attached to the drive to verify that the unit follows the provisions of the European Low Voltage and EMC Directives Directive 73 23 EEC as amended by 93 68 EEC and Directive 89 336 EEC as amended by 2004 108EC Definitions EMC stands for Electromagnetic Compatibility It is the ability of electrical electronic equipment to operate without problems within an electromagnetic environment Likewise the equipment must not disturb or interfere with any other product or system within its locality First environment includes establishments connected to a low voltage network which supplies buildings used for domestic purposes Second environment includes establishments connected to a network not supplying domestic premises Drive of category C2 drive of rated voltage less than 1000 V and intended to be installed and commissioned only by a professional when used in the first environment Note A professional is a person or organisation having necessary
43. terminal labelling YYFY IIR 73 Note on external power supply 00 RR ms 73 Parameter settings cao A a a hn ates 73 External control connections non US ene 74 External control connections US 75 RMIO board specifications n orien Z Toled s cR ROE KE Y FF FR FR eet eae 76 Analogue inputs nmm oe AO Pa mun P L TE IR RENE 76 Constant voltage output 2 2 rs 76 Auxiliary power oUtput oisi hr Woolard eet ora TA AL we TR Uk a 76 Analogue outputs lt lt 55 2 2 eton W eR ln Pa eat crue eg 76 Digital inputs a i PL PRI L GW eee ee eh A 76 Relay outputs ss em eo ke K QE ERE ao RE RE AE o A TT DDGS fibre optic link Z x 2i reme A CY de GE 77 24V DE power input xo ofr ee rte Pi at selon ed eut Rl d UDD dE 7T Installation checklist Checklist o 79 Maintenance What this chapter contains o s s sss ek Re des Ren bye aad ibe has ni 81 Safety x vot A Vou eue A ESL E EDI IUe 81 Maintenance intervals eem RR RR ARE n 81 Heatsink ce o 0 GL A o or ae aie 82 FAN eiie AN razy E Mod Ai o ZNA sue quet ended yn mde O ees Oe ND RR o O 82 Fan replacement R2 R3 ue ba as Mete YAA d deeded AA MUR 82 Fan replacement R4 a rub Eel Iud ua Me ERREUR Ip 83 Fan replacement RB e ne 84 Fan replacement RO 2 a eu Ar GA P EUR papa e emere P UR ER ETE 85 Additional fan ae ses tee dean AER A YD AH AT RP PERI EE IDEA Te WA 85 Replacement R2 R3 ueu uu ul en eere Ste ei t De tat 85
44. the drive input or output terminals U1 V1 W1 U2 V2 W2 UDC UDC Alternative 2 Measure that there is no voltage present on the drive input or output terminals U1 V1 W1 U2 V2 W2 UDC UDC Ground the drive output terminals temporarily by connecting them together as well as to the PE Alternative 3 If possible both of the above Start up and operation overvoltage which may damage or explode the capacitors in the intermediate circuit WARNING Do not run the motor over the rated speed Motor overspeed leads to A of the drive Controlling a permanent magnet motor is only allowed using the control program for Permanent Magnet Synchronous Machine Drive or other control programs in scalar control mode Safety instructions Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 12 Safety instructions Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 13 Table of contents AC 8800 Single Drive Manuals m 2 Safety instructions What this Chapter contains ca egg R ssec m e Rak Y Y A i 5 Use of warnings and noles s x onse ur etak dene ace tebe eee RIA GG UN ARA dd 5 Installation and maintenance work VFF FFF FF EF FF FR m ii 6 Grounding ee ga vhs SER ER LAS d MO yy A TRA a ed EM GA 7 Mechanical installation and maintenance 1 FF FFF RF e 8 Printed circuit boards ee user eR EET pees FYR a 9 Fibre optic cables
45. the setting of parameter 21 09 If stop by coasting is required select OFF2 STOP For the use of the brake resistor overload protection parameters 27 02 27 05 consult an ABB representative enabled by parameter setting the brake resistor must be disconnected because the A WARNING If the drive is equipped with a brake chopper but the chopper is not protection against resistor overheating is then not in use For settings of other control programs see the appropriate firmware manual Resistor braking Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 147 External 24 V power supply for the RMIO board via terminal X34 What this chapter contains This chapter describes how to connect an external 24 V power supply for the RMIO board via terminal X34 For the current consumption of the RMIO board see chapter Motor Control and I O Board RMIO Note External power is easier to supply to the RMIO board via terminal X23 see chapter Motor Control and I O Board RMIO Parameter settings In Standard Control Program set parameter 16 09 CTRL BOARD SUPPLY to EXTERNAL 24V if the RMIO board is powered from an external supply External 24 V power supply for the RMIO board via terminal X34 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 148 Connecting 24 V external power supply Break off the tab covering the 24 VDC power input con
46. transformer with static screening between the primary and secondary windings can be used Medium voltage network Supply transformer Neighbouring network Static screen Point of measurement Low voltage Equipment victim Equipment e Low voltage L Equipment zl z 2 An EMC plan for preventing disturbances is drawn up for the installation A template is available from the local ABB representative 3 The motor and control cables are selected as specified in the Hardware Manual 4 The drive is installed according to the instructions given in the Hardware Manual WARNING A drive of category C4 is not intended to be used on a low voltage public network which supplies domestic premises Radio frequency interference is expected if the drive is used on such a network Machinery Directive The drive complies with the European Union Machinery Directive 98 37 EC requirements for an equipment intended to be incorporated into machinery Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 112 C tick marking C tick marking is required in Australia and New Zealand A C tick mark is attached to each drive in order to verify compliance with the relevant standard IEC 61800 3 2004 Adjustable speed electrical power drive sys
47. 0 2 4 7 5 3 R2 35 160 0009 3 13 9 17 6 5 5 12 7 5 5 9 3 4 R2 35 200 0011 3 19 24 7 5 18 7 5 14 5 5 R3 69 250 0016 3 25 32 11 24 11 19 1 5 R3 69 340 0020 3 34 46 15 31 15 23 11 R3 69 440 0025 3 44 62 22 41 18 5 32 15 R4 103 530 0030 3 55 72 30 50 22 37 18 5 R4 103 610 0040 3 72 86 37 69 30 49 22 R5 250 810 0050 3 86 112 45 80 37 60 30 R5 250 990 0060 3 103 138 55 94 45 69 37 R5 250 1190 0075 3 145 170 75 141 75 100 45 R5 405 1440 0070 3 141 164 75 132 55 97 45 R6 405 1440 0100 3 166 202 90 155 75 115 55 R6 405 1940 0120 3 202 282 110 184 90 141 75 R6 405 2310 0135 3 225 326 110 220 110 163 90 R6 405 2810 0165 3 260 326 132 254 132 215 110 R6 405 3260 0205 3 290 351 160 285 160 234 132 R6 405 4200 Three phase supply voltage 380 V 400 V 415 V 440 V 460 V 480 V or 500 V 0004 5 4 9 6 5 2 2 45 2 2 3 4 1 5 R2 35 120 0005 5 6 2 8 2 3 5 6 3 4 2 2 2 R2 35 140 0006 5 8 1 108 4 7 7 4 5 6 3 R2 35 160 0009 5 10 5 13 8 5 5 10 5 5 1 5 4 R2 35 200 0011 5 13 2 17 6 1 5 12 7 5 9 2 5 5 R2 35 250 0016 5 19 24 11 18 11 13 1 5 R3 69 340 0020 5 25 32 15 23 15 18 11 R3 69 440 0025 5 34 46 18 5 31 18 5 23 15 R3 69 530 0030 5 42 62 22 39 22 32 18 5 R4 103 610 0040 5 48 72 30 44 30 36 22 R4 103 810 0050 5 65 86 37 61 37 50 30 R5 250 990 0060 5 79 112 45 75 45 60 37 R5 250 1190 0070 5 96 138 55 88 55 69 45 R5 250 1440 0105 5 145 170 90 141 90 100 55 R5 405 2150 0100 5 124 164 75 115 75 88 55 R6 405 1940 0120 5 157 202 90 145 90 113 75
48. 0 65 n 0205 3 and 0255 5 units H1 is 38 46 in and weight is 150 Ib Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 107 Input power connection Voltage U4 Short circuit withstand strength IEC 60439 1 Short circuit current protection UL 508 C CSA C22 2 No 14 05 Frequency Imbalance Fundamental power factor cos phi4 Motor connection 208 220 230 240 V AC 3 phase 10 for 230 V AC units 380 400 415 V AC 3 phase 10 for 400 V AC units 380 400 415 440 460 480 500 V AC 3 phase 10 for 500 V AC units 525 550 575 600 660 690 V AC 3 phase 10 for 690 V AC units Maximum allowable prospective short circuit current is 65 kA when protected by fuses given in the EC data fuse tables US and Canada The drive is suitable for use on a circuit capable of delivering not more than 100 kA rms symmetrical amperes at the drive nominal voltage when protected by fuses given in the NEMA data fuse table 48 to 63 Hz maximum rate of change 17 s Max 3 of nominal phase to phase input voltage 0 98 at nominal load Voltage U2 Frequency Frequency resolution Current Power limit Field weakening point Switching frequency Maximum recommended motor cable length Efficiency 0 to U4 3 phase symmetrical Umax at the field weakening point DTC mode 0 to 3 2 feyp Maximum frequency 300 Hz UNmains fewp
49. 00 500 ABB Control OFAF000H80 000 0050 3 83 1480 100 63600 500 ABB Control OFAF000H100 000 0060 3 100 1940 125 103000 500 ABB Control OFAF00H125 00 0075 3 142 2400 160 200000 500 ABB Control OFAF00H160 00 0070 3 138 2400 160 200000 500 ABB Control OFAF00H160 00 0100 3 163 2850 200 350000 500 ABB Control OFAF1H200 1 0120 3 198 3300 224 420000 500 ABB Control OFAF1H224 1 0135 3 221 3820 250 550000 500 ABB Control OFAF1H250 1 0165 3 254 4510 315 1100000 500 ABB Control OFAF2H315 2 0205 3 286 4510 315 1100000 500 ABB Control OFAF2H315 2 Three phase supply voltage 380 V 400 V 415 V 440 V 460 V 480 V or 500 V 0050 5 64 1050 80 34500 500 ABB Control OFAF000H80 000 0060 5 78 1480 100 63600 500 ABB Control OFAF000H100 000 0070 5 95 1940 125 103000 500 ABB Control OFAF00H125 00 0105 5 142 2400 160 200000 500 ABB Control OFAF00H160 00 0100 5 121 2400 160 200000 500 ABB Control OFAF00H160 00 0120 5 155 2850 200 350000 500 ABB Control OFAF1H200 1 0140 5 180 2850 200 350000 500 ABB Control OFAF1H200 1 0165 5 222 3820 250 550000 500 ABB Control OFAF1H250 1 0205 5 256 4510 315 1100000 500 ABB Control OFAF2H315 2 0255 5 286 4510 315 1100000 500 ABB Control OFAF2H315 2 Three phase supply voltage 525 V 550 V 575 V 600 V 660 V or 690 V 0050 7 52 740 63 28600 690 ABB Control OFAA0GG63 0 0060 7 58 740 63 28600 690 ABB Control OFAA0GG63 0 0070 7 79 1050 80 52200 690 ABB Control OFAA0GG80 0 0100 7 91 1480 100 93000 690 ABB Control OFAA1GG100 1
50. 00 8 e i 2 e e amp e Y gt d e L 0781 GE g if p J S A 7 ai NI wa m hal s 6761 067 5 U 5 JGGUUU na E o 2 g lt 1 uj 820220 rb o o Ly 2 e NI m amp o x o s Dimensional drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Frame size R4 IP 55 UL type 12 123 lt I M N FANE N T o PL o o U A y UJ E Es 6 e o o o o o 0 81 GT m f ik i i TI 5 67617 06 i 7 14 84 ES lt 1 a R OE TE a a E 6507 vil T ue 8 8 Dimensional drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 124 Frame size R5 IP 21 UL type 1 s 3 5 f mmm ja I Dimensional drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com
51. 00 Bussmann JJS 10 T 0004 2 R2 92 15 600 Bussmann JJS 15 T 0006 2 R3 18 25 600 Bussmann JJS 25 T 0009 2 R3 24 30 600 Bussmann JJS 30 T 0011 2 R3 31 40 600 Bussmann JJS 40 T 0016 2 R4 38 50 600 Bussmann JJS 50 T 0020 2 R4 49 70 600 Bussmann JJS 70 T 0025 2 R5 64 90 600 Bussmann JJS 90 T 0030 2 R5 75 100 600 Bussmann JJS 100 T 0040 2 R5 102 125 600 Bussmann JJS 125 T 0050 2 R6 126 175 600 Bussmann JJS 175 T 0060 2 R6 153 200 600 Bussmann JJS 200 T 0070 2 R6 190 250 600 Bussmann JJS 250 T Three phase supply voltage 380 V 400 V 415 V 440 V 460 V or 480 V 0004 5 R2 4 1 10 600 Bussmann JJS 10 g 0005 5 R2 5 4 10 600 Bussmann JJS 10 T 0006 5 R2 6 9 10 600 Bussmann JJS 10 T 0009 5 R2 9 8 15 600 Bussmann JJS 15 T 0011 5 R2 13 20 600 Bussmann JJS 20 T 0016 5 R3 18 25 600 Bussmann JJS 25 T 0020 5 R3 24 35 600 Bussmann JJS 35 T 0025 5 R3 31 40 600 Bussmann JJS 40 T 0030 5 R4 40 50 600 Bussmann JJS 50 T 0040 5 R4 52 70 600 Bussmann JJS 70 T 0050 5 R5 63 80 600 Bussmann JJS 80 T 0060 5 R5 77 100 600 Bussmann JJS 100 T 0070 5 R5 94 125 600 Bussmann JJS 125 T 0105 5 R5 138 150 600 Bussmann JJS 150 T 0100 5 R6 121 150 600 Bussmann JJS 150 T 0120 5 R6 155 200 600 Bussmann JJS 200 g 0140 5 R6 179 225 600 Bussmann JJS 225 T 0205 5 R6 243 350 600 Bussmann JJS 350 T Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 105
52. 1 0030 7 28 SACE15RE22 22 420 2 0040 7 22 33 T SACE15RE22 22 420 2 0050 7 45 SACE15RE13 13 435 2 0060 7 56 SACE15RE13 13 435 2 0070 7 68 SAFUR90F575 8 1800 4 5 0100 7 83 SAFUR90F575 8 1800 4 5 0120 7 113 SAFUR80F500 6 2400 6 0145 7 160 SAFUR80F500 6 2400 6 0175 7 160 SAFUR80F500 6 2400 6 0205 7 160 SAFUR80F500 6 2400 6 PDM code 00096931 J PprcontThe drive and the chopper will withstand this continuous braking power The braking is considered continuous if the braking time exceeds 30 s Note Check that the braking energy transmitted to the specified resistor s in 400 seconds does not exceed Ep R Resistance value for the listed resistor assembly Note This is also the minimum allowed resistance for the brake resistor ER Short energy pulse that the resistor assembly withstands every 400 seconds This energy will heat the resistor element from 40 C 104 F to the maximum allowable temperature Pgcont Continuous power heat dissipation of the resistor when placed correctly Energy Eg dissipates in 400 seconds 4 22 kW with standard 22 ohm resistor and 33 kW with 32 37 ohm resistor All braking resistors must be installed outside the converter module The SACE brake resistors are built in an IP 21 metal housing The SAFUR brake resistors are built in an IP 00 metal frame Note The SACE and SAFUR resistors are not UL listed Resistor installation and wiring All resistors must be installed outside the driv
53. 1 Loosen the screws that fasten the fan mounting plate to the frame 2 Push the fan mounting plate to the left and pull it out 3 Disconnect the fan power cable 4 Undo the screws that fasten the fan to the fan mounting plate 5 Install the new fan in reverse order Bottom view View from above fan plate pulled out Maintenance Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 84 Fan replacement R5 1 Undo the fastening screws of the swing out frame 2 Open the swing out frame 3 Disconnect the cable 4 Undo the fastening screws of the fan 5 Install the new fan in reverse order Bottom view Maintenance Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 85 Fan replacement R6 To remove the fan undo the fixing screws Disconnect the cable Install the new fan in reverse order Note In 0205 3 and 0255 5 units access the fan through the opening in the support frame when changing the fan Bottom view Additional fan There is an additional cooling fan in all IP 55 units and most IP 21 units However there is no additional fan in the following IP 21 units 0003 3 0004 3 0004 5 0005 5 and 0006 5 The following IP 55 units have two additional fans 0205 3 and 0255 5 Replacement R2 R3 Remove the front cover To remove the fan release the retaining clip 1 Disconnect the cabl
54. 2 An EMC plan for preventing disturbances is drawn up for the installation A template is available from the local ABB representative 3 The motor and control cables are selected as specified in the Hardware Manual 4 The drive is installed according to the instructions given in the Hardware Manual WARNING A drive of category C4 is not intended to be used on a low voltage public network which supplies domestic premises Radio frequency interference is expected if the drive is used on such a network Marine type approvals See ACS800 01 U1 04 U4 Marine Supplement 3AFE68291275 English Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 114 UL CSA markings The ACS800 01 and ACS800 U1 units of UL type 1 are C UL US listed and CSA marked UL The drive is suitable for use on a circuit capable of delivering not more than 100 kA rms symmetrical amperes at the drive nominal voltage 600 V maximum for 690 V units when protected by fuses given in the NEMA data fuse table The ampere rating is based on tests done according to UL 508C The drive provides overload protection in accordance with the National Electrical Code US See AC S800 Firmware Manual for setting Default setting is off must be activated at start up The drives are to be used in a heated indoor controlled environment See section Ambient conditions for specific limits Brake chopper ABB has brake choppers th
55. 22 x22 and ARSE00 0F oo J1 DI Stop Start 1 Only effective if par 10 03 is set to 2 12 DI2 Forward Reverse 1 REQUEST by the user 3 F 13 DI3 Not in use 4 14 DIA Acceleration 8 deceleration select 2 2 0 open 1 closed 5 15 DI5 Constant speed select DI4 Ramp times according to 6 16 DI6 Constant speed select 9 O parameters 22 02 and 22 03 7 17 24VD 424 V DC max 100 mA 1 parameters 22 04 and 22 05 8 1 18 24VD 3 See par group 12 CONSTANT CON Digital ground SPEEDS 10 410 DGND2 Digital ground DI5 DI6 Operation 11 r 111 DIL Start interlock 0 stop 4 0 O Set speed through Al1 X23 X23 1 0 Constant speed 1 1 1 24V Auxiliary voltage output and input non O 1 Constant speed 2 2 2 GND isolated 24 V DC 250 mA 5 1 1 Constant speed 3 X25 X25 1 eg RO1 Relay output 1 ready 4 See parameter 21 09 START INTRL 2 1 12 ROT 5 Lm current shared 13 between this output and optional X26 X26 modules installed on the board 1 13 RO2 Relay output 2 running 2 12 ROZ 3 13 RO2 x27 X27 1 UO RO3 Relay output 3 fault 1 Fault 2 12 ROS 7 3 13 RO3 Motor control and I O board RMIO Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 75 External control connections US External control cable connections to the RMIO board for the ACS800 Standard Control Program Factory Macro US version are shown below For extern
56. 24 86 75 62 60 R6 238 5650 0120 7 172 108 100 86 75 R6 238 6700 0145 7 190 125 125 99 100 R6 238 9100 0175 7 245 155 150 131 125 R6 238 11850 0205 7 245 192 200 147 150 R6 238 14300 PDM code 00096931 J Overload may be limited to 5 at high speeds gt 90 speed by the internal power limit of the drive The limitation also depends on motor characteristics and network voltage Overload may be limited to 40 at high speeds gt 90 speed by the internal power limit of the drive The limitation also depends on motor characteristics and network voltage gus special 4 pole high efficiency NEMA motor higher rating is available with special 4 pole high efficiency NEMA motor Symbols Nominal ratings Imax maximum output current Available for 10 s at start otherwise as long as allowed by drive temperature Normal use 10 overload capability lon continuous rms current 10 overload is typically allowed for one minute every 5 minutes Py typical motor power The power ratings apply to most 4 pole NEMA rated motors 230 V 460 V or 575 V Heavy duty use 50 overload capability lona continuous rms current 50 overload is typically allowed for one minute every 5 minutes Pha typical motor power The power ratings apply to most 4 pole NEMA rated motors 230 V 460 V or 575 V Note 1 The ratings apply at an ambient temperature of 40 C 104 F In lower temperatures the ratings are higher except Imax Sizin
57. 3 4773 Web www clrwtr com Email info clrwtr com 56 Frame size R5 o Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 57 Frame size R6 Cable lug installation 16 to 70 mm 6 to 2 0 AWG cables a IJ Isolate the ends of a the cable lugs with insulating tape or shrink tubing Connection plate fastening screws a Connect the cable to the terminal b Connect the terminal to the drive WARNING If the wire size is less than A 95 mm 3 0 AWG a cable lug must be used A cable of wire size less than 95 mm 3 0 AWG connected to this terminal will loosen and may damage the drive Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 58 Wall installed units US version 1 Remove the front cover in frame size R6 the lower front cover by releasing the retaining clip with a screw driver and lifting the cover from the bottom outwards Make the cable entry holes in the gland box by breaking off the suitable knock out plates with a screw driver 3 Fasten the cable glands to the opened holes of the gland box 4 Fasten the gland box to the frame with two screws three screws in frame size R6 Frame sizes R2 to R4 Input power cable Motor cable 5 Lead the cables through the glands to the inside of the gland box 6 Connect
58. 55 5 286 2620 550 190000 690 Bussmann 170M5811 DIN2 Three phase supply voltage 525 V 550 V 575 V 600 V 660 V or 690 V 0050 7 52 400 100 4650 690 Bussmann 170M1567 000 Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 98 Ultrarapid aR fuses AC S800 01 size Input Min Fuse current short circuit current 1 A A AZs V Manufacturer Type IEC size 0060 7 58 400 100 4650 690 Bussmann 170M1567 000 0070 7 79 520 125 8500 690 Bussmann 170M1568 000 0100 7 91 695 160 16000 690 Bussmann 170M1569 000 0120 7 112 750 200 15000 690 Bussmann 170M3815 1 0145 7 131 1520 350 68500 690 Bussmann 170M3818 DIN1 0175 7 162 1520 350 68500 690 Bussmann 170M3818 DIN1 0205 7 186 1610 400 74000 690 Bussmann 170M5808 DIN2 T minimum short circuit current of the installation Note 1 See also Planning the electrical installation Thermal overload and short circuit protection For UL recognized fuses see NEMA data on page 102 Note 2 In multicable installations install only one fuse per phase not one fuse per conductor Note 3 Larger fuses than the recommended ones must not be used Note 4 Fuses from other manufacturers can be used if they meet the ratings and the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table PDM code 00096931 J 00556489
59. 800 4 5 0050 3 45 SAFUR90F575 8 1800 4 5 0060 3 56 SAFUR90F575 8 1800 4 5 0075 3 70 SAFUR80F500 6 2400 6 0070 3 68 SAFUR80F500 6 2400 6 0100 3 83 SAFUR125F500 4 3600 9 0120 3 113 SAFUR125F500 4 3600 9 0135 3 132 SAFUR200F500 2 7 5400 13 5 0165 3 132 SAFUR200F500 2 7 5400 13 5 0205 3 160 SAFUR200F500 2 7 5400 13 5 500 V units 0004 5 1 5 SACE08RE44 44 210 1 0005 5 2 2 SACEOBRE44 44 210 1 0006 5 3 0 SACEOBRE44 44 210 1 0009 5 4 0 SACE08RE44 44 210 1 0011 5 5 5 SACE08RE44 44 210 1 0016 5 7 5 SACE15RE22 22 420 2 0020 5 11 SACE15RE22 22 420 2 0025 5 15 SACE15RE22 22 420 2 0030 5 28 SACE15RE13 13 435 2 0040 5 33 SACE15RE13 13 435 2 0050 5 45 SAFUR90F575 8 1800 4 5 0060 5 56 SAFUR90F575 8 1800 4 5 0070 5 68 SAFUR90F575 8 1800 4 5 0105 5 83 SAFUR80F500 6 2400 6 0100 5 83 SAFUR125F500 4 3600 9 0120 5 113 SAFUR125F500 4 3600 9 0140 5 135 SAFUR125F500 4 3600 9 0165 5 160 SAFUR125F500 4 3600 9 0205 5 160 SAFUR125F500 4 3600 9 0255 5 200 SAFUR200F500 2 7 5400 13 5 Resistor braking Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 144 AC S800 01 type Braking power Brake resistor s ACS800 U1 type of the chopper and the drive Pprcont Type R ER PRcont kW ohm KJ kW 690 Vunits 0011 7 8 SACE08RE44 44 210 1 0016 7 11 SACE08RE44 44 210 1 0020 7 16 SACE08RE44 44 210 1 0025 7 22 SACE08RE44 44 210
60. 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 93 AC S800 01 Input Fuse size current A AZs V Manufacturer Type IEC size Three phase supply voltage 380 V 400 V or 415 V 0003 3 4 7 10 483 500 ABB Contro OFAF000H10 000 0004 3 6 0 10 483 500 ABB Control OFAF000H10 000 0005 3 7 9 10 483 500 ABB Control OFAF000H10 000 0006 3 10 16 993 500 ABB Control OFAF000H16 000 0009 3 13 16 993 500 ABB Control OFAF000H16 000 0011 3 17 20 1620 500 ABB Control OFAF000H20 000 0016 3 23 25 3100 500 ABB Control OFAF000H25 000 0020 3 32 40 9140 500 ABB Control OFAF000H40 000 0025 3 42 50 15400 500 ABB Control OFAF000H50 000 0030 3 53 63 21300 500 ABB Control OFAF000H63 000 Three phase supply voltage 380 V 400 V 415 V 440 V 460 V 480 V or 500 V 0004 5 4 7 10 483 500 ABB Control OFAF000H10 000 0005 5 5 9 10 483 500 ABB Control OFAF000H10 000 0006 5 7 7 10 483 500 ABB Control OFAF000H10 000 0009 5 10 0 16 993 500 ABB Control OFAF000H16 000 0011 5 12 5 16 993 500 ABB Control OFAF000H16 000 0016 5 17 20 1620 500 ABB Control OFAF000H20 000 0020 5 23 25 3100 500 ABB Control OFAF000H25 000 0025 5 31 40 9140 500 ABB Control OFAF000H40 000 0030 5 41 50 15400 500 ABB Control OFAF000H50 000 0040 5 47 63 21300 500 ABB Control OFAF000H63 000 Three phase supply voltage 525 V 550 V 575 V 600 V 660 V or 690
61. AC 5800 Hardware Manual ACS800 01 Drives 0 55 to 200 kW AC S800 U1 Drives 0 75 to 200 HP NONI KU A Eb ED FADED Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com ACS800 Single Drive Manuals HARDWARE MANUALS appropriate manual is included in the delivery ACS800 01 U1 Hardware Manual 0 55 to 200 kW 0 75 to 200 HP 3AFE64382101 English ACS800 01 U1 04 Marine Supplement 0 55 to 160 kW 0 75 to 200 HP 3AFE68291275 English ACS800 11 U11 Hardware Manual 5 5 to 110 KW 7 5 to 125 HP 3AFE68367883 English ACS800 31 U31 Hardware Manual 5 5 to110 kW 7 5 to 125 HP 3AFE68599954 English ACS800 02 U2 Hardware Manual 90 to 500 kW 125 to 600 HP 3AFE64567373 English ACS800 04 U4 Hardware Manual 0 55 to 200 kW 0 75 to 200 HP 3AFE68372984 English ACS800 04 04M U4 Hardware Manual 45 to 560 kW 60 to 600 HP 3AFE64671006 English ACS800 04 04M U4 Cabinet Installation 45 to 560 kW 60 to 600 HP 3AFE68360323 English ACS800 07 U7 Hardware Manual 45 to 560 kW 50 to 600 HP 3AFE64702165 English ACS800 07 U7 Dimensional Drawings 45 to 560 kW 50 to 600 HP 3AFE64775421 ACS800 07 Hardware Manual 500 to 2800 kW 3AFE64731165 English ACS800 17 Hardware Manual 55 to 2500 kW 75 to 2800 HP 3AFE68397260 English ACS800 37 Hardware Manual 55 to 2700 kW 75 to 3000 HP 3AFE68557925 English Safety instructions Electrical installation p
62. ACS800 01 Drives Code 3AUA0000068944 Rev B 0 55 to 200 kW and ACS800 U1 Drives 0 75 to 200 HP Valid from 01 09 2010 until the release of the next revision of Hardware Manuals the manual Code Revision Language Contents 3AFE64382101 3AFE64526146 3AFE64526120 3AFE64526197 The headings in this update notice refer to the modified subsections in the original English manual Each heading also includes a page number and a classifier NEW CHANGED or German DE DELETED The page number refers to the page number in the Spanish original English manual The classifier describes the type of the modification English Danish 3AFE64526502 Finnish 3AFE64526545 French FR 3AFE64526596 Italian IT 3AFE64526618 Dutch 3AFE64526634 Portuguese Russian Swedish SV 3AFE64526669 3AFE64526693 c c c c lt lt cc lt lt O NEW page 6 Safety Installation and maintenance work After maintaining or modifying a drive safety circuit or changing circuit boards inside the module retest the functioning of the safety circuit according to the start up instructions Do not change the electrical installations of the drive except for the essential control and power connections Changes may affect the safety performance or operation of the drive unexpectedly All customer made changes are on the customer s responsibility Note The Safe torque off fun
63. Bussmann 170M1567 DINOOO 0030 2 81 520 125 8500 690 Bussmann 170M1568 DINOOO 0040 2 101 695 160 8500 690 Bussmann 170M1569 DINOOO 0050 2 138 1630 315 80500 690 Bussmann 170M1572 DINOOO 0060 2 163 1280 315 46500 690 Bussmann 170M3817 DIN1 0070 2 202 1810 400 105000 690 Bussmann 170M3819 DIN1 Three phase supply voltage 380 V 400 V or 415 V 0040 3 69 400 100 4650 690 Bussmann 170M1567 DINOOO 0050 3 83 520 125 8500 690 Bussmann 170M1568 DINOOO 0060 3 100 695 160 8500 690 Bussmann 170M1569 DINOOO 0075 3 142 1630 315 80500 690 Bussmann 170M1572 DINOOO 0070 3 138 1630 315 80500 690 Bussmann 170M1572 DINOOO 0100 3 163 1280 315 46500 690 Bussmann 170M3817 DIN1 0120 3 198 1810 400 105000 690 Bussmann 170M3819 DIN1 0135 3 221 2210 500 145000 690 Bussmann 170M5810 DIN2 0165 3 254 2620 550 190000 690 Bussmann 170M5811 DIN2 0205 3 286 2620 550 190000 690 Bussmann 170M5811 DIN2 Three phase supply voltage 380 V 400 V 415 V 440 V 460 V 480 V or 500 V 0050 5 64 400 100 4650 690 Bussmann 170M1567 DINOOO 0060 5 78 520 125 8500 690 Bussmann 170M1568 DINOOO 0070 5 95 520 125 8500 690 Bussmann 170M1568 DINOOO 0105 5 142 1630 315 80500 690 Bussmann 170M1572 DINOOO 0100 5 121 1630 315 80500 690 Bussmann 170M1572 DINOOO 0120 5 155 1280 315 46500 690 Bussmann 170M3817 DIN1 0140 5 180 1810 400 105000 690 Bussmann 170M3819 DIN1 0165 5 222 2210 500 145000 690 Bussmann 170M5810 DIN2 0205 5 256 2620 550 190000 690 Bussmann 170M5811 DIN2 02
64. E di Penh tee we WYF Radon es ae bis 39 FA ISGS sd mn A tu ordre be ci nU RL osx ND ID 39 Main contactors ct ie dried cerco Fs DOR e ore pateret e AO TA a TR 39 Thermal overload and short circuit protection ee 40 Thermal overload protection of the drive and the input and motor cables 40 Thermal overload protection of the motor sls 40 Protection against short circuit in the motor cable Y Fu ug 40 Protection against short circuit inside the drive or in the supply cable 41 FUSES ada iR dro b sur NSA ANN ah E deu ert tom du dy AE 41 Gircuit breaker 15 eny nee ands tie er RARE DRIVE UE Ra eae Ed eae Y 41 Ground fault protection esee Se ey Se He pex EU ETE ee eA 42 Prevention of Unexpected Sant Y FF FR FF FF uy 42 Selecting the power cables FF FFF ehh 43 General rules a eu du wn AAA RE E CU E es 43 Alternative power cable types YF FFF FF me 44 Motorzcable shield toa ea cta ds AST e kol te es iet AU 44 Additional US requirements YF FF FF FF rn 45 Conduit eu cu o ea daa best baden m efe A Gw Yy gd PA do 45 Armored cable shielded power cable YF FF ua 45 Power factor compensation capacitors YY FY FFF e 45 Equipment connected to the motor cable FF FF FR nh 46 Installation of safety switches contactors connection boxes etc 46 Bypass connection uei ge Gyng EN Ad AU NE RR WD YNA UY GY A FF 46 Before op
65. Email info clrwtr com 125 Frame size R5 IP 55 UL type 12 1 6177 S78 M M s 0077 709 d ro i 2 U U lh M fe 8 SIL a 3 3 Dimensional drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 126 Frame size R6 IP 21 UL type 1 6977 088 64646231 B Dimensional drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 127 Frame size R6 IP 21 UL type 1 205 3 and 255 5 units Note Only measurements that differ from those of the standard Frame size R6 IP 21 UL type 1 are given below s e MSS q 00000 lt s 60000 T 10 5 wo 3 S S S FF lt a lt 5 Dimensional drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Ema
66. Email info clrwtr com 44 Alternative power cable types Power cable types that can be used with the drive are represented below Recommended Symmetrical shielded cable three phase conductors A separate PE conductor is required if the conductivity and a concentric or otherwise symmetrically of the cable shield is 5096 of the conductivity of the constructed PE conductor and a shield phase conductor PE conductor hield and shield S PE PE PE Shield A four conductor system three phase conductors QUO C and a protective conductor Not allowed for motor cables Not allowed for motor cables with phase conductor cross section larger than 10 mm motors gt 30 kW 40 HP Motor cable shield To effectively suppress radiated and conducted radio frequency emissions the shield conductivity must be at least 1 10 of the phase conductor conductivity The requirements are easily met with a copper or aluminium shield The minimum requirement of the motor cable shield of the drive is shown below It consists of a concentric layer of copper wires with an open helix of copper tape or copper wire The better and tighter the shield the lower the emission level and bearing currents Copper wire screen Helix of copper tape Inner insulation or copper wire Insulation jacket Cable core Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwt
67. HP symmetrical shielded motor cable must be used figure below A four conductor system can be used up to frame size R4 with up to 30 kW 40 HP motors but shielded symmetrical motor cable is always recommended The shield s of motor cable s must have 360 bonding at both ends Note When continuous metal conduit is employed shielded cable is not required The conduit must have bonding at both ends as with cable shield A four conductor system is allowed for input cabling but shielded symmetrical cable is recommended To operate as a protective conductor the shield conductivity must be as follows when the protective conductor is made of the same metal as the phase conductors Cross sectional area of the phase Minimum cross sectional area of the conductors corresponding protective conductor S mm Sp mm S lt 16 S 16 lt S lt 35 16 35 lt S S 2 Compared to a four conductor system the use of symmetrical shielded cable reduces electromagnetic emission of the whole drive system as well as the stress on motor insulation bearing currents and wear The motor cable and its PE pigtail twisted shield should be kept as short as possible in order to reduce high frequency electromagnetic emission as well as stray currents outside the cable and capacitive current relevant in power range below 20 kW Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com
68. N 60947 2 US The disconnecting means must conform to the applicable safety regulations Fuses See section Thermal overload and short circuit protection Main contactor If used dimension the contactor according to the nominal voltage and current of the drive The utilization category IEC 947 4 is AC 1 Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 40 Thermal overload and short circuit protection Thermal overload protection of the drive and the input and motor cables The drive protects itself and the input and motor cables against thermal overload when the cables are dimensioned according to the nominal current of the drive No additional thermal protection devices are needed Switch or a circuit breaker must be used for protecting each cable and motor These WARNING If the drive is connected to multiple motors a separate thermal overload devices may require a separate fuse to cut off the short circuit current Thermal overload protection of the motor According to regulations the motor must be protected against thermal overload and the current must be switched off when overload is detected The drive includes a motor thermal protection function that protects the motor and switches off the current when necessary Depending on a drive parameter value the function either monitors a calculated temperature value based on a motor ther
69. Prd A A od A kw A kw mh W Three phase supply voltage 208 V 220 V 230 V or 240 V 0001 2 5 1 6 5 1 1 4 7 0 75 3 4 0 55 R2 35 100 0002 2 6 5 8 2 1 5 6 0 1 1 4 3 0 75 R2 35 100 0003 2 8 5 10 8 1 5 7 7 1 5 5 7 1 1 R2 35 100 0004 2 10 9 13 8 2 2 10 2 2 2 75 1 5 R2 35 120 0005 2 13 9 17 6 3 12 7 3 9 3 2 2 R2 35 140 0006 2 19 24 4 18 4 14 3 R3 69 160 0009 2 25 32 5 5 24 5 5 19 4 R3 69 200 0011 2 34 46 7 5 31 4 5 23 5 5 R3 69 250 0016 2 44 62 11 42 11 32 7 5 R4 103 340 0020 2 55 72 15 50 11 37 7 5 R4 103 440 0025 2 72 86 18 5 69 18 5 49 11 R5 250 530 0030 2 86 112 22 80 22 60 15 R5 250 610 0040 2 103 138 30 94 22 69 18 5 R5 250 810 0050 2 141 164 37 132 37 97 30 R6 405 1190 0060 2 166 202 45 155 45 115 30 R6 405 1190 0070 2 202 282 55 184 55 141 37 R6 405 1440 Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 90 ACS800 01 size Nominal No Light overload Heavy duty use Frame Air flow Heat ratings overload use size dissipation Icont max Imax Peont max lu PN lohd Prd i A E A kW A kW m h w Three phase supply voltage 380 V 400 V or 415 V 0003 3 5 1 6 5 1 5 4 7 1 5 34 1 1 R2 35 100 0004 3 6 5 82 2 2 5 9 2 2 4 3 1 5 R2 35 120 0005 3 8 5 10 8 3 7 7 3 5 7 2 2 R2 35 140 0006 3 10 9 13 8 4 1
70. Replacement R4 R5 0 001 86 Replacement R6 cnu dia o EE hr dE ed 86 Capacitors see ar enS maru lana PON KNE T Se named PO ear RP re figa 86 Reforming nau mutetur eter I aua do ee A NF NET E AE d 86 LEDS a e eer oct trate eru e Sede re ra e Gals au aar e e RR kN ene A 87 Technical data What this chapter contains FF FFR FF I un 89 enr cm sarune t E orate Sata te abet e edie ty nd geek aaa a WED Le 89 Rating Sc cos Aa od NE eon SD Wage Miele Seid VERE emer UR QURE rn e ota o 89 Symbols ako RA e A ao O a AJ ERA GA JE cues 91 SIZING eus ou Set EAE NIU E QU A E IER PLA iam 91 Derating eiu ues aa e dl nak K OEE eo NAF wae YS ERRA Rr annals Deewana tes 92 Temperature derating Y YY YR tet uu 92 Altitude derating ww ay od GR dr e BW dd WNO AUD AA YDI RA bee 92 Table of contents Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com FUSOS K om ue e dtes VE Laat at pales o Tog bise WA 92 Frame sizes R2 to RA coca erobern RR PRU RR E on ede do 92 Erame sizes RO andi RO au oed rs o ead edu Duo AI IUE IER K 94 Calculation example 4 2454 500 2 z ni a i DG RAD dade 94 Fuse tables for frame sizes R5 and R6 eese 96 Standard GG fuses i ea hese Y WW Yy AI e rius 96 Ultrarapid AR fuses ui uter RE mper erre ide aa e de endo oe tert 97 Quick guide for selecting between gG and aR fuses 99 Gable types 40 14 00 1 eae a Vana de
71. S800 01 U1 ACS800 04 04M ACS800 11 U11 ACS800 31 U31 ACS800 02 with enclosure extension The main switch on the cabinet door does not remove the voltage from the input busbars of the drive Before working on the drive isolate the whole drive from the supply ACS800 01 U1 ACS800 04 04M ACS800 11 U11 ACS800 31 U31 The Prevention of Unexpected Start function does not remove the voltage from the main and auxiliary circuits Safety instructions Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com At installation sites above 2000 m 6562 ft the terminals of the RMIO board and optional modules attached to the board do not fulfil the Protective Extra Low Voltage PELV reguirements stated in EN 50178 Grounding These instructions are intended for all who are responsible for the grounding of the drive WARNING Ignoring the following instructions can cause physical injury death increased electromagnetic interference and equipment malfunction e Ground the drive motor and adjoining equipment to ensure personnel safety in all circumstances and to reduce electromagnetic emission and interference Make sure that grounding conductors are adequately sized as required by safety regulations In a multiple drive installation connect each drive separately to protective earth PE ACS800 01 ACS800 11 ACS800 31 In European CE compliant installations and in other installations wher
72. The cable trays must have good electrical bonding to each other and to the grounding electrodes Aluminium tray systems can be used to improve local equalizing of potential Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 50 A diagram of the cable routing is shown below Motor cable Drive Powarc ble min 300 mm 12 in Input power cable Motor cable min 200 mm 8 in 90 LI min 500 mm 20 in Control cables Control cable ducts 230 V 230 V 24V 120V 24V 120V Not allowed unless the 24 V cable is Lead 24 V and 230 V 120 V control insulated for 230 V 120 V or insulated cables in separate ducts inside the with an insulation sleeving for 230 V cabinet 120 V Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 91 Electrical installation What this chapter contains This chapter describes the electrical installation procedure of the drive electrician Follow the Safety instructions on the first pages of this manual Ignoring WARNING The work described in this chapter may only be carried out by a qualified the safety instructions can cause injury or death Make sure that the drive is disconnected from the mains input power during installation If the drive is already connected to the mains wait for 5
73. a group 500 V AC 1 min 15 V DC 2 60 dB at 50 Hz 0 025 12 bit for the 10 V 10 V input 0 5 11 bit for the O 10 V and O 20 mA inputs 0 5 Full Scale Range at 25 c 77 SF Temperature coefficient 100 ppm C 256 ppm F max Voltage Maximum load Applicable potentiometer Auxiliary power output 10 V DC 0 10 V DC 0 5 Full Scale Range at 25 C 77 F Temperature coefficient 100 ppm C 56 ppm F max 10 mA 1 kohm to 10 kohm Voltage Maximum current Analogue outputs 24 V DC 10 short circuit proof 250 mA shared between this output and optional modules installed on the RMIO Resolution Inaccuracy Digital inputs Two programmable current outputs O 4 to 20 mA RL lt 700 ohm 0 1 10 bit 1 Full Scale Range at 25 c 77 F Temperature coefficient 200 ppm C 111 ppm F max Insulation test voltage Logical thresholds Input current Filtering time constant With Standard Control Program six programmable digital inputs common ground 24 V DC 15 to 20 and a start interlock input Group isolated can be divided in two isolated groups see solation and grounding diagram below Thermistor input 5 mA lt 1 5 kohm 2 1 normal temperature gt 4 kohm 2 O high temperature open circuit 0 high temperature Internal supply for digital inputs 24 V DC short circuit proof An external 24 V DC supply can be u
74. ake chopper in frame sizes R2 and R3 230 400 500 V units and in frame size R4 690 V units boards without coating one set of English manuals Size Refer to Technical data IEC data or NEMA data Voltage range 2 208 220 230 240 V AC nominal rating in bold 3 380 400 415 V AC 5 380 400 415 440 460 480 500 V AC 7 525 575 600 690 V AC options Degree of protection B056 IP 55 UL type 12 Construction C131 vibration dampers C132 marine type approved unit coated boards included C131 required for frame sizes R4 to R6 in wall installations C131 not required in cabinet installations Resistor braking D150 brake chopper Filter E200 EMC RFI filter for second environment TN grounded system drive category C3 frame sizes R2 R5 E202 EMC RFI filter for first environment TN grounded system drive category C2 E210 EMC RFI filter for second environment TN IT grounded ungrounded system drive category C3 frame size R6 only Cabling H358 US UK gland conduit box Control panel 0J400 no control panel Fieldbus Kis Refer to ACS800 Ordering Information EN code 64556568 1 0 L Control program N Manual language R Safety features Q950 Prevention of unexpected start Specialities P901 coated boards The ACS800 01 U1 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 25 Main circuit and control Diagram This diagram shows the control interfaces and the main circuit
75. al control connections of other control macros and programs see the appropriate Firmware Manual x2 RMIO RMIO X20 X20 Terminal block size 1 EE BU VREF Reference voltage 10 V DC 1 kohm RL cables 0 3 to 3 3 mm 22 to 12 AWG 12 AGND lt 10 kohm Tightening torgue x21 x21 0 2 to 0 4 Nm 0 2 to 0 3 Ibf ft 11 11 VREF Reference voltage 10 V DC 1 kohm lt R lt x 12 12 AGND 10kohm 13 13 Al1 Speed reference 0 2 10 V Rin 114 1 14 Al1 200 kohm 5 215 Al2 By default not in use 0 4 20 mA Rin 6 16 Al2 100 ohm 7 17 AI3 By default not in use 0 4 20 mA Rin 8 18 AI3 100 ohm en 9 19 AO1 Motor speed 0 4 20 mA 0 motor nom 10 110 AO1 speed RL lt 700 ohm A 11 stint AO2 Output current 0 4 20 mA 2 0 motor 1 112 f 112 AO2 nom current R lt 700 ohm X22 X22 1 1 11 on Start 17 La Lel 2 12 DI2 Stop 1 optional terminal block in ACS800 U2 3 13 DI3 Forward Reverse 1 dn 4 bo ja DI4 Acceleration 8 deceleration select 2 1 Only effective if par 10 03 is set to SS 5 15 DI5 Constant speed select 3 REGUEST by the user 6 16 DI6 Constant speed select 3
76. al data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 106 Cable Entries Brake resistor input and motor cable per phase terminal sizes accepted cable diameters and tightening torgues are given below Frame U1 V1 W1 U2 V2 W2 R R Earthing PE size Wire size Knock out hole Y Tightening Wire size Tightening UL type 1 torgue torgue AWG in Ibf ft AWG Ibf ft R2 up to 6 1 10 0 9 1 1 up to 8 1 1 R3 up to 6 1 14 0 9 1 1 up to 8 1 4 R4 up to 4 1 38 1 5 3 0 up to 5 22 R5 10 2 0 1 97 11 1 10 2 0 11 1 R6 3 0 350 AWG T 2 40 T 14 8 29 5 4 0 5 9 6 AWG rigid solid cable 8 AWG flexible stranded cable with cable lugs 6 2 0 AWG tightening torque 14 8 29 5 Ibf ft Cable lugs are not included in the delivery See page 57 In 0205 3 and 0255 5 units wire size is 3 0 500 MCM and knockout hole diameter is 3 50 in Dimensions weights and noise H1 height with gland box H2 height without gland box Frame UL type 1 UL type 12 Noise size H1 H2 Width Depth Weight Height Width Depth Weight in in in in Ib in in in Ib dB R2 15 96 14 57 6 50 8 89 20 20 78 10 35 9 49 34 62 R3 18 54 16 54 6 81 10 45 31 20 78 10 35 10 74 41 62 R4 23 87 19 29 9 45 10 79 57 30 49 14 84 10 94 73 62 R5 29 09 23 70 10 43 11 26 75 30 49 14 84 12 14 112 65 R6 34 65 27 56 11 81 15 75 148 36 34 16 52 16 54 17
77. arth potential through the EMC filter capacitors which may cause danger or damage the unit Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 111 Second environment drive of category C3 The drive complies with the standard with the following provisions 1 Frame sizes R2 R5 The drive is eguipped with EMC filter E200 The filter is suitable for TN earthed systems only Frame size RG The drive is eguipped with EMC filter E210 The filter is suitable for TN earthed and IT unearthed systems 2 The motor and control cables are selected as specified in the Hardware Manual 3 The drive is installed according to the instructions given in the Hardware Manual 4 Maximum cable length is 100 metres WARNING A drive of category C3 is not intended to be used on a low voltage public network which supplies domestic premises Radio frequency interference is expected if the drive is used on such a network Second environment drive of category C4 If the provisions under Second environment drive of category C3 cannot be met e g the drive cannot be equipped with EMC filter E200 when installed to an IT unearthed network the requirements of the standard can be met as follows 1 Itis ensured that no excessive emission is propagated to neighbouring low voltage networks In some cases the inherent suppression in transformers and cables is sufficient If in doubt a supply
78. at when applied with appropriately sized brake resistors will allow the drive to dissipate regenerative energy normally associated with quickly decelerating a motor Proper application of the brake chopper is defined in chapter Resistor braking US patents This product is protected by one or more of the following US patents 4 920 306 5 301 085 5 463 302 5 521 483 5 532 568 5 589 754 5 612 604 5 654 624 5 799 805 5 940 286 5 942 874 5 952 613 6 094 364 6 147 887 6 175 256 6 184 740 6 195 274 6 229 356 6 252 436 6 265 724 6 305 464 6 313 599 6 316 896 6 335 607 6 370 049 6 396 236 6 448 735 6 498 452 6 552 510 6 597 148 6 600 290 6 741 059 6 774 758 6 844 794 6 856 502 6 859 374 6 922 883 6 940 253 6 934 169 6 956 352 6 958 923 6 967 453 6 972 976 6 977 449 6 984 958 6 985 371 6 992 908 6 999 329 7 023 160 7 034 510 7 036 223 7 045 987 7 057 908 7 059 390 7 067 997 7 082 374 7 084 604 7 098 623 7 102 325 7 109 780 7 164 562 7 176 779 7 190 599 7 215 099 7 221 152 7 227 325 7 245 197 7 250 739 7 262 577 7 271 505 7 274 573 7 279 802 7 280 938 7 330 095 7 349 814 7 352 220 7 365 622 7 372 696 7 388 765 D503 931 D510 319 D510 320 D511 137 D511 150 D512 026 D512 696 D521 466 D541 7438 D541 7448 D541 745S D548 1828 D548 183S Equipment warranty and liability The manufacturer warrants the equipment supplied against defects in design materials and workmanship for a period of twelve 12 months after installation or twenty four 24 mo
79. ation and reflection properties of the motor cable and the terminals This in turn can cause additional stress on the motor and motor cable insulation Modern variable speed drives with their fast rising voltage pulses and high switching frequencies can generate current pulses that flow through the motor bearings which can gradually erode the bearing races and rolling elements The stress on motor insulation can be avoided by using optional ABB du dt filters du dt filters also reduce bearing currents To avoid damage to motor bearings the cables must be selected and installed according to the instructions given in the hardware manual In addition insulated N end non driven end bearings and output filters from ABB must be used according to the following table Two types of filters are used individually or in combinations optional du dt filter protects motor insulation system and reduces bearing currents common mode filter mainly reduces bearing currents Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Reguirements table 35 The following table shows how to select the motor insulation system and when an optional ABB du dt filter insulated N end non driven end motor bearings and ABB common mode filters are required The motor manufacturer should be consulted regarding the construction of the motor insulation and additional requirements for ex
80. back plate to the drive frame with two screws three screws in frame size R6 Cut adequate holes into the rubber grommets and slide the grommets onto the cables Slide the cables through the holes of the bottom plate Strip off the plastic sheath of the cable under the 360 degrees grounding clamp Fasten the clamp onto the stripped part of the cable Connect the twisted shield of the cable to the grounding terminal Note cable lugs are needed in frame sizes R2 and R3 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 Fasten the bottom plate of the connection box with two screws to the already fastened back plate and slide the grommets into their place Secure the cables outside the unit mechanically Connect the control cables as described in section Connecting the control cables Fasten the covers see Fastening the control cables and covers Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 55 Connection box IP 21 Back plate Fastening hooks Fastening screws A Motor cable entry Bottom plate Fasten the control cables between these plates with cable ties Input power cable Motor cable Brake resistor cable entry Electrical installation Phone 800 894 0412 Fax 888 72
81. cations without prior notice Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 116 Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 117 Dimensional drawings Dimensional drawings of the ACS800 01 are shown below The dimensions are given in milllimetres and inches Dimensional drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 118 Frame size R2 IP 21 UL type 1 m L iD N N M o 7 678 Y U e SIT ymn A A 7 NA A TON hm EE A o Ju a B G r rel re KZ A Lry 09 zl 1671 OLE 00 c a R p JA gi o Ss O O 00 O 8 00000 a C J ES OOO OO 1 CG gt 688 977 E R E NI 3 3 Dimensional drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 119 Frame size R2 IP 55 UL type 12
82. chapter contains the safety instructions which you must follow when installing operating and servicing the drive If ignored physical injury or death may follow or damage may occur to the drive motor or driven eguipment Read the safety instructions before you work on the unit Use of warnings and notes There are two types of safety instructions throughout this manual warnings and notes Warnings caution you about conditions which can result in serious injury or death and or damage to the equipment They also tell you how to avoid the danger Notes draw attention to a particular condition or fact or give information on a subject The warning symbols are used as follows Dangerous voltage warning warns of high voltage which can cause physical injury and or damage to the equipment electricity which can result in physical injury and or damage to the equipment 1 General warning warns about conditions other than those caused by Electrostatic discharge warning warns of electrostatic discharge which 4 can damage the equipment Hot surface warning warns of hot surfaces which can cause physical N injury Safety instructions Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Installation and maintenance work These warnings are intended for all who work on the drive motor cable or motor damage to the eguipment A WARNING Ignoring the following instructions can cause physical inj
83. chnical data of the ASTO 11C board Note Maximum cable length between ASTO terminal block X2 and the drive terminal block is restricted to 3 metres Connect the ASTO board as follows Remove the cover of the enclosed ASTO unit by undoing the fixing screws 1 Ground the ASTO unit via the bottom plate of the enclosure or via terminal X1 2 or X1 4 of the ASTO board Connect the cable delivered with the kit between terminal block X2 of the ASTO board 2 and drive terminal block X41 WARNING Use only the ASTO cable delivered the the kit Using another cable or modifying the cable may cause a malfunction of the drive Connect a cable between connector X1 of the ASTO board 3 and the 24 V Source Fasten the cover of the ASTO unit back with screws Update Notice Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Update Notice Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Circuit diagram The diagram below shows the connection between the ASTO board and the drive when it is ready For an example diagram of a complete Safe torque off circuit see page 3 in this Update Notice ASTO KIT I Drive I 1 i 1 1 1 1 1 1 1 1 1 1 1 1 1 1 ii 1 1 1 1 1 1 1 i gt A431 i 1 1 I ASTO
84. com Email info clrwtr com 36 Motor type Nominal mains Reguirement for i es AC line Motor insulation ABB du dt filter insulated N end bearing and ABB common mode E voltage system filter 9 Py lt 100 kW 100 kW lt Py lt 350 kW Py gt 350 kW 3 and or or s frame size lt IEC 315 frame size gt IEC 315 frame size gt IEC 400 Py lt 134 HP 134 HP lt Py lt 469 HP Py gt 469 HP and frame size lt or frame size gt or frame size gt NEMA 500 NEMA 500 NEMA 580 N Random Un lt 420 V Standard l N or CMF N CMF o wound and 1300 V N formwound 420 V lt Uy lt 500 V Standard D du dt du dt N du dt N CMF 1300 V or B du dt CMF B or B Reinforced UL N or CMF N CMF 1600 V 0 2 microsecond rise time 500 V lt Uy x 600 V Reinforced U du dt du dt N du dt N CMF 1600 V or du dt CMF or Reinforced Uy N or CMF N CMF 1800 V 600 V lt Un lt 690 V Reinforced UL du dt du dt N du dt N CMF 1800 V Reinforced Uy N CMF N CMF 2000 V 0 3 microsecond rise time manufactured before 1 1 1998 For motors manufactured before 1 1 1998 check for additional instructions with the motor manufacturer f the intermediate DC circuit voltage of the drive is increased from the nominal level by resistor braking or by the IGBT Supply C
85. copper shield Max load Cable type Max load Cable type current current A mm A mm 13 3x1 5 61 3x25 18 3x2 5 69 3x35 24 3x4 83 3x50 30 3x6 107 3x70 42 3x10 130 3x95 56 3x16 151 3x120 71 3x25 174 3x150 88 3x35 199 3x185 107 3x50 235 3x240 137 3x70 274 3 x 3x50 167 3x95 260 2 x 3x95 193 3x120 223 3x150 255 3x185 3BFA 01051905 C Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 101 Cable entries Brake resistor mains and motor cable terminal sizes per phase accepted cable diameters and tightening torgues are given below Frame U1 V1 W1 U2 V2 W2 R R Earthing PE size Wire size Max cable Cable Y Tightening Wire size Tightening IP 21 IP 55 torgue torgue mm mm mm Nm mm Nm R2 up to 16 21 14 20 1 2 1 5 up to 10 1 5 R3 up to 16 21 14 20 12 1 5 up to 10 1 5 R4 up to 25 29 23 35 2 4 up to 16 3 0 R5 6 70 35 23 35 15 6 70 15 R6 95 240 63 30 45 20 40 95 8 16 mm rigid solid cable 10 mm flexible stranded cable with cable lugs 16 70 mm tightening torque 20 40 Nm Cable lugs are not included in the delivery See page 57 Dimensions weights and noise H1 height with cable connection box H2 height without cable connection box Frame IP 21 IP 55 Noise size H1 H2 Width Depth Weight Height Width Depth Weight mm mm m
86. ction option Q967 does not remove the voltage from the main and auxiliary circuits CHANGED page 11 Safety Permanent magnet motor Ensure that the motor cannot rotate during work Prevent the start up of any drives in the same mechanical group by opening the Prevention of unexpected start switch option Q950 or the Safe torque off switch option Q967 and padlocking it Make sure that no other system like hydraulic crawling drives are able to rotate the motor directly or through any mechanical connection like felt nip rope etc Update Notice Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com NEW page 20 Contents Installation of ASTO board Safe torque off Q967 contains electrical installation instructions of the optional Safe torque off function Q967 of the drive and specifications of the board NEW page 24 Type code The table below contains the new option code definition for the Safe torque off function Code Description Q967 Safe torque off STO NEW page 43 Safe torque off The drive supports the Safe torque off STO function according to standards EN 61800 5 2 2007 EN ISO 13849 1 2008 IEC 61508 and EN 62061 2005 The function also corresponds to an uncontrolled stop in accordance with category 0 of EN 60204 1 and prevention of unexpected start up of EN 1037 The STO may be used where power removal is required to prevent an unexp
87. d ded DD ie ae Bat 100 Gable eritrigS a ous aa Seas tae eiit areas on AS Wa ean es WW RA oU 101 Dimensions weights and noise 00 FFF FF FF uu 101 NEMA Gata i bu ea ieee nite an Pen ed ded A 102 cune EP 102 Symbols 4 o6 OL hE ee oe tates AR SI eM yd DUE A LV y 103 iral P a o A U DA 103 Derating Mau R T if SO A quis aee c me dudes 103 FUSOS 5e meo ioc Kasta PORA CANA a e deter M NA E ds 104 CADIS AV POS ee caet ne err Seas O ge ep va R la di deus quee tes 105 Cable Entes oet e o P INCL REY PE Sr EE AEN MEA ERA 106 Dimensions weights and noise eh 106 Input power connection ee ERRARE RUM Re d RE da 107 Motor connection x och nas eU EIER Ae AT cds Sa tha FN we ce PA FR 107 EMicIeNCY M R BEM MD M ac D ec EU RP M CE 107 GOOJIRG ct ecce va P Maga Mos tuk asa RA REO amie Sa ante ayes 108 Degrees of protection i e ei aun eE K pb ni tede ba RP ELEME NAA MEN dedu d deis 108 Ambient Conditoris Jes zy dae dete MO A etat unte wa PAW A INT Ace miS Pecado 108 Materials 54 oe a ir eai ee thee und ect Bac ee DA 109 Applicable standards ee coded Rp e ORDRE ERR Wn ROSE ee Ro er ee 109 CE marKing ee dee tec re T OL Gees de bud TE RE IEEE ERES 110 Definitions 24 24084 ua pU EXE ERA NE OWA EET SR E I dU AU dae s 110 Compliance with the EMC Directive FFF FF FF Rug 110 Compliance with the EN 61800 3 2004 0 000 see 110 First environment drive of category C2 VYY Y FI aaa a ania 110 Seco
88. dule 3 RDCO 1 Place the warning sticker here Control cable grounding see Detachable connection terminals pull up section 360 z l degrees a AW Terminal for optional grounding 21 E Prevention of Unexpected Start Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 64 360 degrees grounding Insulation L IK Double shielded cable Single shielded cable When the outer surface of the shield is covered with non conductive material Strip the cable carefully do not cut the grounding wire and the shield Turn the shield inside out to expose the conductive surface Wrap the grounding wire around the conductive surface Slide a conductive clamp onto the conductive part Fasten the clamp to the grounding plate with a screw as close as possible to the terminals where the wires are about to be connected Connecting the shield wires Single shielded cables Twist the grounding wires of the outer shield and connect them through the shortest possible route to the nearest grounding hole with a cable lug and a screw Double shielded cables Connect each pair cable shield twisted grounding wires with other pair cable shields of the same cable to the nearest grounding hole with a cable lug and a screw Do not connect shields of different cables to the same cable lug and grounding Screw Leave the other
89. e 2 detachable terminal Install the new fan in reverse order kd BERRN Eu Air flow upwards 2 P Rotation direction View from above when front cover is removed Maintenance Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 86 Replacement R4 R5 Remove the front cover The fan is located on the lower right hand side of the unit R4 or on the right hand side of the control panel R5 Lift the fan out and disconnect the cable Install the fan in reverse order Replacement R6 Remove the top cover by lifting it by the rear edge To remove the fan release the retaining clips by pulling the back edge 1 of the fan upwards Disconnect the cable 2 detachable terminal Install the new fan in reverse order 4 Air flow upwards P Rotation direction View from above when top cover is removed Capacitors The drive intermediate circuit employs several electrolytic capacitors Their lifespan is from 45 000 to 90 000 hours depending on drive loading and ambient temperature Capacitor life can be prolonged by lowering the ambient temperature It is not possible to predict a capacitor failure Capacitor failure is usually followed by a mains fuse failure or a fault trip Contact ABB if capacitor failure is suspected Replacements for frame size R4 and up are available from ABB Do not use other than ABB specified spare parts Reforming Reform re age spare par
90. e EMC emissions must be minimized make a 360 high frequency grounding of cable entries in order to suppress electromagnetic disturbances In addition connect the cable shields to protective earth PE in order to meet safety regulations ACS800 04 45 to 560 kW and ACS800 02 in first environment make a 360 high frequency grounding of motor cable entries at the cabinet lead through Do not install a drive with EMC filter option E202 or E200 available for ACS800 01 and ACS800 11 ACS800 31 only on an ungrounded power system or a high resistance grounded over 30 ohms power system Note Power cable shields are suitable for equipment grounding conductors only when adequately sized to meet safety regulations As the normal leakage current of the drive is higher than 3 5 mA AC or 10 mA DC stated by EN 50178 5 2 11 1 a fixed protective earth connection is required Safety instructions Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Mechanical installation and maintenance These instructions are intended for all who install and service the drive WARNING Ignoring the following instructions can cause physical injury or death or damage to the equipment A Handle the unit carefully e ACS800 01 ACS800 11 ACS800 31 The drive is heavy Do not lift it alone Do not lift the unit by the front cover Place the unit only on its back ACS800 02 ACS800 04 The drive is heav
91. e cooling air flow service and maintenance is shown below in millimetres and inches When mounting IP 55 units above one another leave 200 mm 7 9 in free space above and below the unit 200 7 9 50 2 0 gt po 2 0 1 Eg Q OO jJ oooool 00000 O 50 2 0 gt e 300 12 50 2 0 4 IP 55 UL 12 IP 21 UL 1 SOX S AS Air flow side view Mechanical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 30 Mounting the drive on the wall Units without vibration dampers 1 Mark the locations for the four holes The mounting points are shown in Dimensional drawings In frame sizes R2 to R5 IP 21 UL type 1 use the mounting template cut from the package 2 Fix the screws or bolts to the marked locations 3 IP 55 UL type 12 units Remove the front cover by undoing the fixing screws 4 Position the drive onto the screws on the wall Note Lift the drive by its chassis R6 by its lifting holes not by its cover 5 Tighten the screws in the wall securely OD ge IP 55 UL 12 pa I 1 S S P 4 i F a 4 p X e i IP 55 UL type 12 marine applications C132 of frame sizes R4 to R6 See ACS800 01 U1 Marine Supplement 3AFE68291275 English Units with vibration dampers C131 See ACS800 01 U1 Vibration Damp
92. e module in a place where they will cool WARNING The materials near the brake resistor must be non flammable The surface temperature of the resistor is high Air flowing from the resistor is of hundreds of degrees Celsius Protect the resistor against contact Use the cable type used for drive input cabling refer to chapter Technical data to ensure the input fuses will also protect the resistor cable Alternatively two conductor shielded cable with the same cross sectional area can be used The maximum length of the resistor cable s is 10 m 33 ft For the connections see the power connection diagram of the drive Resistor braking Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 145 Protection of frame sizes R2 to R5 ACS800 01 U1 It is highly recommended to equip the drive with a main contactor for safety reasons Wire the contactor so that it opens in case the resistor overheats This is essential for safety since the drive will not otherwise be able to interrupt the main supply if the chopper remains conductive in a fault situation Below is a simple example wiring diagram L1 L2 L3 1 OFF E gt Fuses 2 1 3 5 13 3 EA sla ON E gt 2 4 5 s 14 4 ACS800 j 5 U1 V1 W1 Ta Thermal switch standard in ABB K1 resistors Protection of frame size R6 A main contactor is not required for pr
93. e operation of the protection cable length i e the longer the cable the weaker the fuse protection as the long cable limits the fault current cable size i e the smaller the cable the weaker the fuse protection as the small cable size limits the fault current transformer size i e the smaller the transformer the weaker the fuse protection as the small transformer limits the fault current transformer impedance i e the higher the z the weaker the fuse protection as high impedance limits the fault current The protection can be improved by installling a larger supply transformer and or bigger cables and in most cases by selecting aR fuses instead of gG fuses Selection of smaller fuses improves the protection but may also affect the fuse life time and lead to unnecessary operation of the fuses In case of any uncertainty regarding the drive protection please contact your local ABB Cable types The table below gives copper and aluminium cable types for different load currents Cable sizing is based on max 9 cables laid on a cable ladder side by side ambient temperature 30 C PVC insulation surface temperature 70 C EN 60204 1 and IEC 60364 5 52 2001 For other conditions size the cables according to local safety regulations appropriate input voltage and the load current of the drive Copper cables with Aluminium cables with concentric copper shield concentric
94. ear and week respectively The remaining digits complete the serial number so that there are no two units with the same serial number The type designation label is attached to the heat sink and the serial number label to the upper part of the back plate of the unit Example labels are shown below now u J 350 500 480 V IP21 UL type 1 NEMA 1 125 19 A cu ABB Oy aan CE amp oc u 3 0 Ulnput V T si i 13 2 14 A 0 300 M AAN A A 31600001 1 60 ACS800 01 0011 5 E202 L503 OAPA Type designation label AC 800 01 0011 5 E202 1503 DU EM TE ter 1031600001 Serial number label Before installation The drive must be installed in an upright position with the cooling section facing a wall Check the installation site according to the requirements below Refer to Dimensional drawings for frame details Requirements for the installation site See Technical data for the allowed operation conditions of the drive Wall The wall should be as close to vertical as possible of non flammable material and strong enough to carry the weight of the unit Check that there is nothing on the wall to inhibit the installation Floor The floor material below the installation should be non flammable Mechanical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 29 Free space around the unit Reguired free space around the drive to enabl
95. ected start The function disables the control voltage of the power semiconductors of the drive output stage thus preventing the inverter from generating the voltage required to rotate the motor see the diagram below By using this function short time operations like cleaning and or maintenance work on non electrical parts of the machinery can be performed without switching off the power supply to the drive Update Notice Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Bi v senes 006x13 dep dsoy 1INOYID ALAAVS ZASH piopX 94 234 008SJv uejs S ow 440_3N080L_34vS enu OIE SPA N3389 HO UMd E L Had 109 7107X oN ZOX ON jeu 88V 6002 LL panouddy al AA E EEES Vine ony ZS ep jno 5045 The w os oR 9 IS 140 4 k Cow L Ave E Meit TORT QNVO8 JOVINALNI LINOMIO NIV XXXX LNIN Zvv y wave gt Lt EZ uw E QuvOS 440 3NDYOL 34Y S OLSV IFN rS 3 T eoe YTI 150 BULOJIUON eS D E a N UOPPIGIO ROLAS SI iJoujno Sseudxe JNOUJIM SonJod pully Ol JNSOJPSIP Jo 9Sn UOnonpoJdog UJU POLIDJUOD UODDUUOJU SU U PUD JUSUUNDOP SIY W SIUDE IO SAJOSOJ SM uoppwojny gay doo
96. ed Start function Q950 of the drive specifications of the board Prevention of Unexpected Start Q950 The optional Prevention of Unexpected Start function includes an AGPS board which is connected to the drive and an external power supply See also chapter Prevention of Unexpected Start page 42 Installation of the AGPS board WARNING Dangerous voltages can be present on the AGPS board even when the A 115 230 V supply is switched off Follow the Safety instructions on the first pages of this manual and the instruction in this chapter when working on tne AGPS board Make sure that the drive is disconnected from the mains input power and the 115 230 V source for the AGPS board is switched off during installation and maintenance If the drive is already connected to the mains wait for 5 min after disconnecting mains power See page 62 for location of terminal block X41 of the drive page 69 for the circuit diagram page 70 for the dimensions of the AGPS board page 71 for the technical data of the AGPS 11C board Note Maximum cable length between AGPS terminal block X2 and the drive terminal block is restricted to 10 metres Installation of AGPS board Prevention of Unexpected Start Q950 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 68 Connect the AGPS board as follows Remove the enclosure cover by undoing the fixing screws 1 Ground the unit v
97. ening a contactor DTC control mode selected a 46 Protecting the relay output contacts and attenuating disturbances in case of inductive loads AT Table of contents Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Selecting the control cables e 48 Relay Cables m 2 esed o dd na SR o TR a 48 Control panel cable Y Y rhe 48 Connection of a motor temperature sensor to the drive MO YY Y Y eee 49 Installation sites above 2000 metres 6562 Tee 49 Rotting the cables I Eso ette qeu err UNES GY Y nd 49 Control cable ducts caia ride eg yc d Ce por R ede E QURE I rere FE 50 Electrical installation What this chapter contains u xeu Lene ve WYR yw PA VAR CURT p eds 51 Checking the insulation of the assembly 52 Drive es T a SS et educ PRA dte ees a Wet Ae ie cte E Er 52 Input cable sexe wand a Bees eA p bea Sees E Pa Re ed ne RUNE 52 Motor and motor Cables uu nt rtr oh oC eee ee be C aac p E X RO SE n 52 IT ungrounded systeri8 ux erede e bg mede wr pel pe eo ce Lege Roe DE e aeg des 52 Connecting the power cables erre 53 Diagram estu A ER e AM ENSE 53 Conductor stripping lengths ss ne 54 Allowed wire sizes tightening torques IIR 54 Wall installed units European versioni eee teens 54 Power cable installation procedure ne 54 Wall installed units US version IR 58 MWarning stle amp Ker i eu
98. er Installation Guide 3AFE68295351 English UL 12 units Install the hood delivered with the drive 50 mm 2 0 in above the top of unit Mechanical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 31 Cabinet installation For better cooling it is recommended to remove the front cover if the unit is installed into a cabinet The required distance between parallel units is five millimetres 0 2 in in installations without the front cover The cooling air entering the unit must not exceed 40 C 104 F Preventing cooling air recirculation Prevent air recirculation inside and outside the cabinet Example HOT Main air flow out AREA iS Air baffle plates X COOL AREA UJ Main air flow in Ji Mechanical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 32 Unit above another Lead the out coming cooling air away from the unit above Example max 40 C 104 F Mechanical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 33 Planning the electrical installation What this chapter contains This chapter contains the instructions that you must follow when selecting the motor cables protections cable routing and way of operation for the drive system
99. eries The Ep value of the four resistor assembly is four times the value specified for the standard resistor Resistor braking Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 142 Note A resistor other than the standard resistor can be used provided that its resistance is not lower than the resistance of the standard resistor WARNING Never use a brake resistor with a resistance below the value specified for the particular drive brake chopper resistor combination The drive and the chopper are not able to handle the overcurrent caused by the low resistance the resistance does not restrict the braking capacity needed i e 2 Upc Pmax lt R where Pmax maximum power generated by the motor during braking Upc voltage over the resistor during braking e g 1 35 1 2 415 V DC when supply voltage is 380 to 415 V AC 1 35 1 2 500 V DC when supply voltage is 440 to 500 V AC or 1 35 1 2 690 V DC when supply voltage is 525 to 690 V AC R resistor resistance ohm the heat dissipation capacity Eg is sufficient for the application see step 3 above Optional brake chopper and resistor s for the ACS800 01 U1 The nominal ratings for dimensioning the brake resistors for the ACS800 01 and ACS800 U1 are given below at an ambient temperature of 40 C 104 F ACS800 01 type
100. erly on a vertical non flammable wall See Mechanical installation O The cooling air will flow freely O The motor and the driven equipment are ready for start See Planning the electrical installation Motor selection and compatibility Technical data Motor connection ELECTRICAL INSTALLATION See Planning the electrical installation Electrical installation O The E202 and E200 EMC filter capacitors are disconnected if the drive is connected to an IT ungrounded system Ll The capacitors are reformed if stored over one year refer to ACS 600 800 Capacitor Reforming Guide 64059629 English O The drive is grounded properly O The mains input power voltage matches the drive nominal input voltage O The mains input power connections at U1 V1 and W1 and their tightening torques are OK O Appropriate mains input power fuses and disconnector are installed Ll The motor connections at U2 V2 and W2 and their tightening torques are OK Ll The motor cable is routed away from other cables Ll There are no power factor compensation capacitors in the motor cable O The external control connections inside the drive are OK O There are no tools foreign objects or dust from drilling inside the drive O Mains input power voltage cannot be applied to the output of the drive with bypass connection O Drive motor connection box and other covers are in place Installation checklist Phone 800 894 0412 Fax 888 723 4773 Web ww
101. es Vibration IEC 60068 2 Max 1 mm 0 04 in 5 to 13 2 Hz max 7 m s 23 ft s 13 2 to 100 Hz sinusoidal Max 1 mm 0 04 in 5 to 13 2 Hz max 7 m s 23 ft s 13 2 to 100 Hz sinusoidal Max 3 5 mm 0 14 in 2 to 9 Hz max 15 m s 49 ft s 9 to 200 Hz sinusoidal Shock IEC 60068 2 29 Not allowed Max 100 m s 330 ft s 11 ms Max 100 m s 330 ft s 11 ms Free fall Not allowed 250 mm 10 in for weight 250 mm 10 in for weight under 100 kg 220 Ib under 100 kg 220 Ib 100 mm 4 in for weight 100 mm 4 in for weight over 100 kg 220 Ib over 100 kg 220 Ib Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Materials 109 Drive enclosure Package Disposal PC ABS 2 5 mm colour NCS 1502 Y RAL 90021 PMS 420 C hot dip zinc coated steel sheet 1 5 to 2 mm thickness of coating 100 micrometres cast aluminium AISi R2 and R3 extruded aluminium AISi R4 to R6 Corrugated cardboard IP 21 units of frame sizes R2 to R5 and option modules plywood frame size R6 and IP 55 units of frame sizes R4 and R5 expanded polystyrene Plastic covering of the package PE LD bands PP or steel The drive contains raw materials that should be recycled to preserve energy and natural resources The package materials are environmentally compatible and recyclable All metal parts can be
102. g See page 9f Derating See page 92 Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 104 Fuses UL class T fuses fuses for branch circuit protection are listed below Fast acting class T or faster fuses are recommended in the USA Check from the fuse time current curve that the operating time of the fuse is below 0 5 seconds for units of frame sizes R2 to R4 and 0 1 seconds for units of frame sizes R5 and R6 The operating time depends on the supply network impedance and the cross sectional area and length of the supply cable The short circuit current can be calculated as shown in section Frame sizes R5 and R6 on page 94 Note 1 See also Planning the electrical installation Thermal overload and short circuit protection Note 2 In multicable installations install only one fuse per phase not one fuse per conductor Note 3 Larger fuses must not be used Note 4 Fuses from other manufacturers can be used if they meet the ratings and the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table ACS800 U1 type Frame size Input Fuse current A A V Manufacturer Type UL class Three phase supply voltage 208 V 220 V 230 V or 240 V 0002 2 R2 5 2 10 600 Bussmann JJS 10 T 0003 2 R2 6 5 10 6
103. ha A A S A kw A kW mn W Three phase supply voltage 525 V 550 V 575 V 600 V 660 V or 690 V 0011 7 13 14 11 11 5 7 5 8 5 5 5 R4 103 300 0016 7 17 19 15 15 11 11 7 5 R4 103 340 0020 7 22 28 18 5 20 15 15 11 R4 103 440 0025 7 25 38 22 23 18 5 19 15 R4 103 530 0030 7 33 44 30 30 22 22 18 5 R4 103 610 0040 7 36 54 30 34 30 27 22 R4 103 690 0050 7 51 68 45 46 37 34 30 R5 250 840 0060 7 57 84 55 52 45 42 37 R5 250 1010 0070 7 79 104 75 73 55 54 45 R6 405 1220 0100 7 93 124 90 86 75 62 55 R6 405 1650 0120 7 113 172 110 108 90 86 75 R6 405 1960 0145 7 134 190 132 125 110 95 90 R6 405 2660 0175 7 166 245 160 155 132 131 110 R6 405 3470 0205 7 190 245 160 180 160 147 132 R6 405 4180 PDM code 00096931 J Symbols the nominal voltage the nominal voltage the nominal voltage The current ratings are the same regardless of the supply voltage within one voltage range To achieve the rated motor power given in the table the rated current of the drive must be higher than or equal to the rated motor current Note 1 The maximum allowed motor shaft power is limited to 1 5 Pha 1 1 Py or Poont max whichever value is greatest If the limit is exceeded motor torque and current are automatically restricted The function protects the input bridge of the drive against overload If the condition exists for 5 minutes the limit is set to Pcont max Note 2 The ratings apply at an ambient temperature of 40 C 104 F At lower tem
104. ia the bottom plate of the enclosure or via terminal X1 1 of the AGPS board Connect the cable delivered with the kit between terminal block X2 of the AGPS board 2 and drive terminal block X41 WARNING Use only the AGPS cable delivered the the kit Using another cable or modifying the cable may cause a malfunction of the drive Connect a cable between connector X1 of the AGPS board 3 and the 115 230 V source Fasten the enclosure cover back with screws 115 230 V Installation of AGPS board Prevention of Unexpected Start Q950 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 69 This circuit diagram shows how the AGPS 11 kit is installed Circuit diagram v66v4 0034V TF z F y 8 ve EE ve EZ B 18 vv pn N 3d 3d subs nouen uopoe1ep vonaejep JIN AU y NP Y RS Se6sag aoa wo S 1 1 1 1 pel I i I i zh i 1 I i 31601 Saran I 4 1 bes _ces _zzs _zis LLX i HA LX i pren Zx 1 A zUX yml I Zo u EX x V ex I I i I o jj NR NRC SEM NARZ I i I IN i r 1 i iino gaua i I 1 1 1 i i SO 1 1V9 OL 820d a H H OLL SdOv V i I moon SL l H 0 10 00gS0V f i i H i UN LL SdOV
105. il info clrwtr com 128 Frame size R6 IP 55 UL type 12 A m a LU X m N en An M e QN o o o o ro NL A 1 9 c L o 5 HE n o z 1697 S79 g ze ec 1 a 1 SL TT Tee vc B s J cal S U U UU U G S las My o d LO 4 o LAN C o o oo RS lt a rg 8 U 00000 a f f 8 f f a A m 9 a 5 H 2 S 8 DO 3 Dimensional drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Frame size R6 IP 55 UL type 12 0205 3 and 0255 5 units e m SIRS I NIE o e lol gisu RE ola i aa R S SD Flplo ka 5 IXS Z lolelo Ee x M r Z eu LI w to ES w gt Y E a gt w a o Bl l ise 1n ii o eu lt qu 17601 v66 9 91 3AUA0000057578 A Supplementary page 3AUA0000057717 2009 04 16 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 129 Dimensional drawings USA Dimensional drawings of the ACS800 U1 are shown below The dimensions are given in milllimetres and inches Dimens
106. in three alternate ways 1 There is double or reinforced insulation between the thermistor and live parts of the motor 2 Circuits connected to all digital and analogue inputs of the drive are protected against contact and insulated with basic insulation the same voltage level as the drive main circuit from other low voltage circuits 3 An external thermistor relay is used The insulation of the relay must be rated for the same voltage level as the main circuit of the drive For connection see ACS800 Firmware Manual Installation sites above 2000 metres 6562 feet the RMIO board wiring and optional modules attached to the board The Protective Extra Low Voltage PELV requirements stated in EN 50178 are not fulfilled at altitudes above 2000 m 6562 ft 0 WARNING Protect against direct contact when installing operating and servicing Routing the cables Route the motor cable away from other cable routes Motor cables of several drives can be run in parallel installed next to each other It is recommended that the motor cable input power cable and control cables be installed on separate trays Avoid long parallel runs of motor cables with other cables in order to decrease electromagnetic interference caused by the rapid changes in the drive output voltage Where control cables must cross power cables make sure they are arranged at an angle as near to 90 degrees as possible Do not run extra cables through the drive
107. ional drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 130 Frame size R2 UL type 1 IP 21 226 8 88 li 0 k ci NE 12 2 Holes ON y o X GO 8 Us SIG e 8 ro m OH U Qi rd x 2 NI amp 2 SE 1 oo FO TI 5 Ht IDa Ns L dAl au ce y OLL gt oo _ dAl T E 599 SZT ES x 8 977 a R 3 Dimensional drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 131 Frame size R2 UL type 12 IP 55 16 1 OZE ANS U Sr Z m 2 SN px ite 2 4 Y 3 3 ON E Em 1 1 pl TTTTTTTT mire Y a La a 007 821 o 2 cj Meet a i 677 9 Eh Ee d 1 28 2 8107 826 2 3 Dimensional drawings Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 132 Frame size R3 UL type 1 IP 21 2091 80
108. irect Torque Control DTC method Two phase currents and DC link voltage are measured and used for the control The third phase current is measured for earth fault protection The ACS800 01 U1 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 27 Mechanical installation Unpacking the unit The drive is delivered in a box that also contains plastic bag containing screws M3 clamps and cable lugs 2 mm M3 for grounding the control cable screens connection box screws clamps and vibration dampers with C 131 included residual voltage warning stickers hardware manual appropriate firmware manuals and guides optional module manuals delivery documents Unpack the unit of frame sizes R2 to R5 IP 21 UL type 1 as follows Do not lift by the cover Mechanical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 28 Delivery check Check that there are no signs of damage Before attempting installation and operation check the information on the type designation label of the drive to verify that the unit is of the correct type The label includes an IEC and NEMA rating UL C UL CSA and CE markings a type code and a serial number which allow individual recognition of each unit The first digit of the serial number refers to the manufacturing plant The next four digits refer to the unit s manufacturing y
109. ive were supplied with 480 V Note 7 Drives with an IGBT supply unit If voltage is raised by the drive this is a parameter selectable function select the motor insulation system according to the increased intermediate circuit DC voltage level especially in the 500 V supply voltage range Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 38 Note 8 Calculating the rise time and the peak line to line voltage The peak line to line voltage at the motor terminals generated by the drive as well as the voltage rise time depend on the cable length The reguirements for the motor insulation system given in the table are worst case reguirements covering installations with 30 metre and longer cables The rise time can be calculated as follows At 0 8 Oj du dt Read and du dt from the diagrams below Multiply the values of the graph by the supply voltage UJ In case of drives with an IGBT supply unit or resistor braking the and du dt values are approximately 20 higher 3 0 5 5 UJUN 5 0 2 5 4 5 2 0 4 0 3 5 1 5 3 0 2 5 1 0 dual is Once 2 0 0 5 1 5 0 0 r r r r r 1 0 r r r r r 100 200 300 100 200 300 Cable length m Cable length m With du at Filter Without du at Filter Note 9 Sine filters protect the motor insulation system Therefore du dt filter can be replaced
110. kers which have been tested by ABB with the ACS800 can be used Fuses must be used with other circuit breakers Contact your local ABB representative for the approved breaker types and supply network characteristics Circuit breaker The protective characteristics of circuit breakers depend on the type construction and settings of the breakers There are also limitations pertaining to the short circuit capacity of the supply network WARNING Due to the inherent operating principle and construction of circuit breakers independent of the manufacturer hot ionized gases may escape from the breaker enclosure in case of a short circuit To ensure safe use special attention must be paid to the installation and placement of the breakers Follow the manufacturer s instructions Note Circuit breakers must not be used without fuses in the USA Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 42 Ground fault protection The drive is eguipped with an internal ground fault protective function to protect the unit against ground faults in the motor and motor cable This is not a personal safety or a fire protection feature The ground fault protective function can be disabled with a parameter refer to the appropriate ACS800 Firmware Manual The EMC filter of the drive includes capacitors connected between the main circuit and the frame These capacitors and
111. lanning Mechanical and electrical installation Motor control and I O board RMIO Maintenance Technical data Dimensional drawings Resistor braking FIRMWARE MANUALS SUPPLEMENTS AND GUIDES appropriate documents are included in the delivery Standard Control Program Firmware Manual 3AFE64527592 English System Control Program Firmware Manual 3AFE64670646 English Application Program Template Firmware Manual 3AFE64616340 English Master Follower 3AFE64590430 English Pump Control Program Firmware Manual 3AFE68478952 English Extruder Control Program Supplement 3AFE64648543 English Centrifuge Control Program Supplement 3AFE64667246 English Traverse Control Program Supplement 3AFE64618334 English Crane Control Program Firmware Manual 3BSE11179 English Adaptive Programming Application Guide 3AFE64527274 English OPTION MANUALS delivered with optional equipment Fieldbus Adapters I O Extension Modules etc Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com AC 8800 01 Drives 0 55 to 200 kW AC S800 U1 Drives 0 75 to 200 HP Hardware Manual 3AFE64382101 Rev J EN EFFECTIVE 1 10 2008 2008 ABB Oy All Rights Reserved Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Update Notice The notice concerns the following
112. lrwtr com 66 Fastening the control cables and covers When all control cables are connected fasten them together with cable ties Units with a connection box fasten the cables to the entry plate with cable ties Units with a gland box tighten the clamping nuts of the cable glands a Fasten the connection box cover Replace the front cover Installation of optional modules and PC The optional module such as fieldbus adapter I O extension module and the pulse encoder interface is inserted in the optional module slot of the RMIO board see Connecting the control cables and fixed with two screws See the appropriate optional module manual for cable connections Fibre optic link A DDCS fibre optic link is provided via the RDCO optional module for PC tools master follower link NDIO NTAC NAIO and fieldbus adapter modules of type Nxxx See RDCO User s Manual for the connections Observe colouring codes when installing fibre optic cables Blue connectors go to blue terminals and grey connectors to grey terminals When installing multiple modules on the same channel connect them in a ring Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 67 Installation of AGPS board Prevention of Unexpected Start Q950 What this chapter contains This chapter describes electrical installation of the optional Prevention of Unexpect
113. m mm kg mm mm mm kg dB R2 405 370 165 226 9 528 263 241 16 62 R3 471 420 173 265 14 528 263 273 18 62 R4 607 490 240 274 26 774 377 278 33 62 R5 739 602 265 286 34 775 377 308 51 65 R6 880 700 300 399 67 923 420 420 77 65 n 0205 3 and 0255 5 units H1 is 977 mm and weight is 70 kg Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 102 NEMA data Ratings The NEMA ratings for the ACS800 U1 with 60 Hz supplies are given below The symbols are described below the table For sizing derating and 50 Hz supplies see IEC data on page 89 ACS800 U1 size Imax Normal use Heavy duty use Frame Air flow Heat size dissipation hn PN lond Pha A A HP A HP ft min BTU Hr Three phase supply voltage 208 V 220 V 230 V or 240 V 0002 2 8 2 6 6 1 5 4 6 1 R2 21 350 0003 2 10 8 8 1 2 6 6 1 5 R2 21 350 0004 2 13 8 11 3 7 5 2 R2 21 410 0006 2 24 21 5 13 3 R3 41 550 0009 2 32 27 7 5 17 5 R3 41 680 0011 2 46 34 10 25 T 5 R3 41 850 0016 2 62 42 15 31 10 R4 61 1150 0020 2 72 54 20 42 15 R4 61 1490 0025 2 86 69 25 54 20 R5 147 1790 0030 2 112 80 30 68 25 R5 147 2090 0040 2 138 104 40 80 30 R5 147 2770 0050 2 164 132 50 104 40 R6 238 3370 0060 2 202 157 60 130 50 R6 238 4050 0070 2 282 192 75
114. mal model or an actual temperature indication given by motor temperature sensors The user can tune the thermal model further by feeding in additional motor and load data The most common temperature sensors are motor sizes IEC180 225 thermal switch e g Klixon motor sizes IEC200 250 and larger PTC or Pt100 See the firmware manual for more information on the motor thermal protection and the connection and use of the temperature sensors Protection against short circuit in the motor cable The drive protects the motor cable and motor in a short circuit situation when the motor cable is dimensioned according to the nominal current of the drive No additional protection devices are needed Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 41 Protection against short circuit inside the drive or in the supply cable Protect the drive and input cable with fuses or a circuit breaker Circuit diagram DRIVE IS NOT EGUIPPED WITH INPUT FUSES Distribution Drive or drive board Input cable module Fuses AH d Circuit breaker Cad A OMA Fuses Size the fuses according to instructions given in chapter Technical data The fuses will protect the input cable in short circuit situations restrict drive damage and prevent damage to adjoining equipment in case of a short circuit inside the drive Circuit brea
115. mas amp Betts 54109 Thomas amp Betts TBM 8 3 2 0 Burndy YAL26T38 Burndy MY29 3 2 sco CRA 2 0 Isco DT 12 sco CCL 2 0 38 Isco MT 25 Thomas amp Betts 54110 Thomas amp Betts TBM 8 3 There are warning stickers in different languages inside the packing box of the drive Attach a warning sticker in the language of your choice onto the plastic skeleton above the power cable terminals Cabinet installation IP 21 UL type 1 The drive can be installed in a cabinet without the connection box and front cover It is recommended to ground the cable shield 360 degrees at the cabinet entry Secure the cables mechanically to lead the cable unstripped as close to the terminals as possible Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 60 Protect the RMIO board terminals X25 to X27 against contact when input voltage exceeds 50 V AC Frame size R5 Cover the power cable terminals as follows 1 Cut holes for the installed cables into the clear plastic shroud 2 Press the shroud onto the terminals Removal of the shroud with a screw driver Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 61 Frame size R6 Cover the power cable terminals as follows 1 Cut holes for the installed cables into the clear plastic shroud in cable lug installations 2 Pre
116. nd Frame sizes R5 and R6 X41 Terminal for optional Prevention of unexpected start Q950 or optional Safe torque off Q967 NEW page 73 Installation of ASTO board Safe torque off Q967 What this chapter contains This chapter describes electrical installation of the optional Safe torque off function Q967 of the drive specifications of the board Safe torque off Q967 The optional Safe torque off function includes an ASTO board which is connected to the drive and an external power supply See also chapter Safe torque off page 2 in this Update Notice Update Notice Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Installation of the ASTO board 24 V supply is switched off Follow the Safety instructions on the first pages of this manual and the instruction in this chapter when working on the ASTO board Make sure that the drive is disconnected from the mains input power and the 24 V source for the ASTO board is switched off during installation and maintenance If the drive is already connected to the mains wait for 5 min after disconnecting mains power WARNING Dangerous voltages can be present at the ASTO board even when the See page 62for location of terminal block X41 of the drive page 7 in this Update Notice for the circuit diagram page 7 in this Update Notice for the dimensions of the ASTO board page 7 in this Update Notice for the te
117. nd environment drive of category C3 VYY YF eee 111 Second environment drive of category CA Y eee 111 Machinery Directive F YL Y Y AF FY FY rr 111 C tick marking e ra dn A FY EIE ITIN DI 112 Definitions ive Go a hate wa te ee ere e pedes E WU REO RE 112 Compliance with IEC 61800 3 VYF e 112 First environment drive of category C2 YY YF Y uu 112 Second environment drive of category C3 VYY Y Y G 113 Second environment drive of category C4 YY Y eee 113 Marine type approvalS e ocz OT a RR os mre Rae UA y 113 UC SA markings we s t oos dn at A Wd AT Y GL Wn AL GEO 114 UE x R t S epus erect FC EWE FN TN AU k O FAAN URP EROR WYN NOD 114 US patentS ee tadas mt Pn naladenia dnn EAT 114 Equipment warranty and liability VY III 114 Dimensional drawings Table of contents Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 18 Frame size R2 IP 21 UL type 1 118 Frame size R2 IP 55 UL type 12 119 Frame size R3 IP 21 UL type 11 YF FFF FF RR FFR Y ad 120 Frame size R3 IP 55 UL type 12 121 Frame size R4 IP 21 UL type T sar RRR a Ran R FI FF R R R RF KRE A R RRR R K R 122 Frame size R4 IP 55 UL type 12 123 Frame size R5 IP 21 UL type To en snr n eame oaa E pE E E EEEE ERA pa OEE E 124 Frame size R5 IP 55 UL type 12 ca a R RER RES RA FF FF Y Y ua
118. nector with pliers Lift the connector upwards Disconnect the wires from the connector keep the connector for later use Isolate the ends of the wires individually with insulating tape Cover the isolated ends of the wires with insulating tape Push the wires inside the skeleton NN O o R O ND Connect the wires of the 24 V external power supply to the disconnected connector if a two way connector wire to terminal 1 and wire to terminal 2 if a three way connector wire to terminal 2 and wire to terminal 3 Plug the connector in Frame sizes R2 to R4 Frame sizes R5 and R6 External 24 V power supply for the RMIO board via terminal X34 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 149 RMIO board i RMIO board 1 2 3 1 2 3 Re A PASZ o e o X34 N 11212 Connection of a two way Connection of a three way connector connector External 24 V power supply for the RMIO board via terminal X34 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com
119. ngth 7 0 082 ohm km Un 430 V 0 072 22 19 mohm ATA 600 kVA ohm R 170 m 0 398 Km 67 66 mohm X 170 m 0 082 Tem 13 94 mohm Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 95 410V lk2 ph 22 7 kA 2 J 67 66 mohm 22 19 mohm 13 94 mohm The calculated short circuit current 2 7 kA is higher than the minimum short circuit current of the drive gG fuse type OFAF00H160 2400 A gt The 500 V gG fuse ABB Control OFAF00H160 can be used Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 96 Fuse tables for frame sizes R5 and R6 Standard gG fuses ACS800 01 size Input Min Fuse current short circuit current 1 A A A s V Manufacturer Type IEC size Three phase supply voltage 208 V 220 V 230 V or 240 V 0025 2 67 1050 80 34500 500 ABB Control OFAF000H80 000 0030 2 81 1480 100 63600 500 ABB Control OFAF000H100 000 0040 2 101 1940 125 103000 500 ABB Control OFAF00H125 00 0050 2 138 2400 160 200000 500 ABB Control OFAF00H160 00 0060 2 163 2850 200 350000 500 ABB Control OFAF1H200 1 0070 2 202 3300 224 420000 500 ABB Control OFAF1H224 1 Three phase supply voltage 380 V 400 V or 415 V 0040 3 69 1050 80 345
120. nment not dusty not clean the heatsink should be checked annually in a dusty environment more often Clean the heatsink as follows when necessary 1 Remove the cooling fan see section Fan 2 Blow clean compressed air not humid from bottom to top and simultaneously use a vacuum cleaner at the air outlet to trap the dust Note If there is a risk of the dust entering adjoining equipment perform the cleaning in another room 3 Refit the cooling fan Fan The cooling fan lifespan of the drive is about 50 000 operating hours The actual lifespan depends on the drive usage and ambient temperature See the appropriate ACS800 firmware manual for an actual signal which indicates the hours of usage of the fan For resetting the running time signal after a fan replacement please contact ABB Fan failure can be predicted by the increasing noise from fan bearings and the gradual rise in the heatsink temperature in spite of heatsink cleaning If the drive is operated in a critical part of a process fan replacement is recommended once these symptoms start appearing Replacement fans are available from ABB Do not use other than ABB specified spare parts Fan replacement R2 R3 To remove the fan release the retaining clips Disconnect the cable Install the new fan in reverse order Bottom view Maintenance Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 83 Fan replacement R4
121. not set to Local L not shown in the status row of the display the stop key on the control panel will not stop the drive To stop the drive using the control panel press the LOC REM key and then the stop key Safety instructions Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 11 Permanent magnet motor These are additional warnings concerning permanent magnet motor drives Ignoring the instructions can cause physical injury or death or damage to the equipment Installation and maintenance work Also when the supply power is switched off and the inverter is stopped a rotating permanent magnet motor feeds power to the intermediate circuit of the drive and the WARNING Do not work on the drive when the permanent magnet motor is rotating supply connections become live Before installation and maintenance work on the drive Stop the motor Ensure that the motor cannot rotate during work Prevent the start up of any drives in the same mechanical group by opening the prevention of unexpected start switch and padlocking it Make sure that no other system like hydraulic crawling drives are able to rotate the motor directly or through any mechanical connection like felt nip rope etc Ensure that there is no voltage on the drive power terminals Alternative 1 Disconnect the motor from the drive with a safety switch or by other means Measure that there is no voltage present on
122. nt and not intended for use in the first environment Drive of category C4 drive of rated voltage equal to or above 1000 V or rated current equal to or above 400 A or intended for use in complex systems in the second environment Compliance with IEC 61800 3 First environment drive of category C2 The drive complies with the limits of IEC 61800 3 with the following provisions 1 The drive is equipped with EMC filter E202 2 The drive is installed according to the instructions given in the Hardware Manual 3 The motor and control cables used are selected as specified in the Hardware Manual 4 Maximum cable length is 100 metres WARNING The drive may cause radio interference if used in a residential or domestic environment The user is required to take measures to prevent interference in addition to the requirements for CE compliance listed above if necessary Note The drive must not be equipped with EMC filter E202 when installed to IT unearthed systems The mains becomes connected to earth potential through the EMC filter capacitors In IT systems this may cause danger or damage the unit Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 113 Second environment drive of category C3 The drive complies with the standard with the following provisions 1 Frame sizes R2 R5 The drive is eguipped with EMC filter E200 The filter is suitable for TN earthed sy
123. nths from date of manufacturing whichever first occurs The local ABB office or distributor may grant a warranty period different to the above and refer to local terms of liability as defined in the supply contract The manufacturer is not responsible for any costs resulting from a failure if the installation commissioning repair alternation or ambient conditions of the drive do not fulfil the requirements specified in the documentation delivered with the unit and other relevant documentation units subjected to misuse negligence or accident units comprised of materials provided or designs stipulated by the purchaser In no event shall the manufacturer its suppliers or subcontractors be liable for special indirect incidental or consequential damages losses or penalties This is the sole and exclusive warranty given by the manufacturer with respect to the equipment and is in lieu of and excludes all other warranties express or implied arising by operation of law or otherwise including but not limited to any implied warranties of merchantability or fitness for a particular purpose Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 115 If you have any questions concerning your ABB drive please contact the local distributor or ABB office The technical data information and specifications are valid at the time of printing The manufacturer reserves the right to modifi
124. ontrol Program parameter selectable function check with the motor manufacturer if additional output filters are needed in the applied drive operation range Note 1 The abbreviations used in the table are defined below Abbreviation Definition Un nominal voltage of the supply network Ou peak line to line voltage at motor terminals which the motor insulation must withstand Pu motor nominal power du dt du dt filter at the output of the drive E205 CMF common mode filter E208 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 Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info BRolrwtr com 37 Note 2 Explosion safe EX motors The motor manufacturer should be consulted regarding the construction of the motor insulation and additional reguirements for explosion safe EX motors Note 3 High output motors and IP 23 motors For motors with higher rated output than what is stated for the particular frame size in EN 50347 2001 and for IP 23 motors the requirements of ABB random wound motor series M3AA M3AP M3BP are given below For other motor types see the Reguirements table above Apply the reguirements of range 100 kW lt Py lt 350 kW to motors with Py
125. or controlling AC motors Control panel CDP312R Heat sink ANN Front cover Connection box IP 21 UL type 1 Control panel CDP312R under a hinged plastic cover Heat sink Front cover no connection box IP 55 UL type 12 The ACS800 01 U1 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 24 Type code The type code contains information on the specifications and configuration of the drive The first digits from left express the basic configuration e g ACS800 01 0006 5 The optional selections are given thereafter separated by signs e g E202 The main selections are described below Not all selections are available for all types For more information refer to ACS800 Ordering Information EN code 64556568 available on request Selection Alternatives Product series ACS800 product series Type 01 wall mounted When no options are selected IP 21 Control Panel CDP312R no EMC filter Standard Control Program cable connection box cabling from below brake chopper in frame sizes R2 and R3 230 400 500 V units and in frame size R4 690 V units boards without coating one set of manuals U1 wall mounted USA When no options are selected UL type 1 Control Panel CDP312R no EMC filter US version of the Standard Control Program three wire start stop as default setting US gland conduit box br
126. or similar equipment are installed in the motor cable between the drive and the motor EU Install the equipment in a metal enclosure with 360 degrees grounding for the shields of both the incoming and outgoing cable or connect the shields of the cables otherwise together US Install the equipment in a metal enclosure in a way that the conduit or motor cable shielding runs consistently without breaks from the drive to the motor Bypass connection and W2 If frequent bypassing is required employ mechanically connected switches or contactors Mains line voltage applied to the output can result in permanent damage to the unit WARNING Never connect the supply power to the drive output terminals U2 V2 Before opening a contactor DTC control mode selected Stop the drive and wait for the motor to stop before opening a contactor between the output of the drive and the motor when the DTC control mode is selected See the appropriate ACS800 control program firmware manual for the required parameter settings Otherwise the contactor will be damaged In scalar control the contactor can be opened with the drive running Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 47 Protecting the relay output contacts and attenuating disturbances in case of inductive loads Inductive loads relays contactors motors cause voltage transients when switched
127. otecting against resistor overheating when the resistor is dimensioned according to the instructions and the internal brake chopper is in use The drive will disable power flow through the input bridge if the chopper remains conductive in a fault situation Note If an external brake chopper outside the drive module is used a main contactor is always required A thermal switch standard in ABB resistors is required for safety reasons The cable must be shielded and not longer than the resistor cable Resistor braking Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 146 With Standard Control Program wire the thermal switch as shown below By default the drive will stop by coasting when the switch opens RMIO X22 or X2 X22 DH DI2 DI3 DI4 DIS DI6 24VD 24VD DGND1 DGND2 DIIL Thermal switch standard in ABB re sistors 9 a ajojo NJO O JA O N gt ked For other control programs the thermal switch may be wired to a different digital input Programming of the input to trip the drive by EXTERNAL FAULT may be needed See the appropriate firmware manual Brake circuit commissioning For Standard Control Program Enable the brake chopper function parameter 27 01 Switch off the overvoltage control of the drive parameter 20 05 Checkthe resistance value setting parameter 27 03 Frame size R6 Check
128. otes 6 and 7 below the Requirements table page 37 4 Consult the motor manufacturer before using a motor in a drive system where the motor nominal voltage differs from the AC power source voltage 5 Ensure that the motor insulation system withstands the maximum peak voltage in the motor terminals See the Requirements table below for the required motor insulation system and drive filtering Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 34 Example 1 When the supply voltage is 440 V and a drive with a diode supply is operating in motor mode only the maximum peak voltage in the motor terminals can be approximated as follows 440 V 1 35 2 1190 V Check that the motor insulation system withstands this voltage Example 2 When the supply voltage is 440 V and the drive is eguipped with an IGBT supply the maximum peak voltage in the motor terminals can be approximated as follows 440 V 1 41 2 1241 V Check that the motor insulation system withstands this voltage Protecting the motor insulation and bearings The output of the drive comprises regardless of output frequency pulses of approximately 1 35 times the equivalent mains network voltage with a very short rise time This is the case with all drives employing modern IGBT inverter technology The voltage of the pulses can be almost double at the motor terminals depending on the attenu
129. peratures the ratings are higher except Imax Note 3 Use the DriveSize PC tool for a more accurate dimensioning if the ambient temperature is below 40 C 104 F or the drive is loaded cyclically Technical data Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 92 Derating The load capacity current and power decreases if the installation site altitude exceeds 1000 metres 3300 ft or if the ambient temperature exceeds 40 C 104 F Temperature derating In the temperature range 40 C 104 F to 50 C 122 F the rated output current is decreased 1 for every additional 1 C 1 8 F The output current is calculated by multiplying the current given in the rating table by the derating factor Example If the ambient temperature is 50 C 122 F the derating factor is 100 1 E 10 C lt 90 or 0 90 The output current is then 0 90 aw or 0 90 long Altitude derating In altitudes from 1000 to 4000 m 3300 to 13123 ft above sea level the derating is 1 for every 100 m 328 ft For a more accurate derating use the DriveSize PC tool See nstallation sites above 2000 metres 6562 feet on page 49 Fuses gG and aR fuses for protection against short circuit in the input power cable or drive are listed below Either fuse type may be used if it operates rapidly enough Frame sizes R2 to R4 Check from the fuse time current curve that the operating time of the
130. plosion safe EX motors Failure of the motor to fulfil the following requirements or improper installation may shorten motor life or damage the motor bearings and voids the warranty Motor type Nominal mains Requirement for E voltage AC line Motorinsulation ABB du dt filter insulated N end bearing and ABB common mode voltage system filter 9 Py lt 100 kW 100 kW lt Py lt 350 kW Py gt 350 kW 3 and or or s frame size lt IEC 315 frame size gt IEC 315 frame size gt IEC 400 Py lt 134 HP 134 HP lt Py lt 469 HP Py gt 469 HP and frame size lt or frame size gt or frame size gt NEMA 500 NEMA 500 NEMA 580 A Random Uy lt 500 V Standard N N CMF B woun yis 500 V lt Uy lt 600 V Standard du dt du dt N du dt N CMF B E or Reinforced N N CMF 600 V lt Uy lt 690 V Reinforced du dt du dt N du dt N CMF Form wound 380 V lt Uy lt 690 V Standard n a N CMF Py lt 500 kW N HX_ and AM_ CMF Py gt 500 kW N CMF du dt Old form 380 V Uy lt 690 V Check with the du dt with voltages over 500 V N CMF wound HX motor and modular manufacturer Random 0V lt Uy lt 500V Enamelled wire N CMF wound HX Tao V lt Uy lt 690 v With fibreglass T qu dt N CMF and AM_ taping Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr
131. r com 45 Additional US reguirements Type MC continuous corrugated aluminum armor cable with symmetrical grounds or shielded power cable must be used for the motor cables if metallic conduit is not used For the North American market 600 V AC cable is accepted for up to 500 VAC 1000 VAC cable is reguired above 500 VAC below 600 VAC For drives rated over 100 amperes the power cables must be rated for 75 C 167 F Conduit Separate parts of a conduit must be coupled together bridge the joints with a ground conductor bonded to the conduit on each side of the joint Bond the conduits also to the drive enclosure and motor frame Use separate conduits for input power motor brake resistor and control wiring When conduit is employed type MC continuous corrugated aluminium armor cable or shielded cable is not required A dedicated ground cable is always required Note Do not run motor wiring from more than one drive in the same conduit Armored cable shielded power cable Six conductor 3 phases and 3 ground type MC continuous corrugated aluminum armor cable with symmetrical grounds is available from the following suppliers trade names in parentheses Anixter Wire amp Cable Philsheath BICC General Corp Philsheath Rockbestos Co Gardex Oaknite CLX Shielded power cables are available from Belden LAPPKABEL LFLEX and Pirelli Power factor compensation capacitors Power factor compensation
132. sed instead of the internal supply 500 V AC 1 min lt 8VDC 2 gt 12V DC 2 1 DI1 to DI 5 10 mA DI6 5 mA 1 ms Motor control and I O board RMIO Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 77 Relay outputs Three programmable relay outputs Switching capacity 8 A at 24 V DC or 250 V AC 0 4 A at 120 V DC Minimum continuous current 5 mA rms at 24 V DC Maximum continuous current 2Arms Insulation test voltage 4 KV AC 1 minute DDCS fibre optic link With optional communication adapter module RDCO Protocol DDCS ABB Distributed Drives Communication System 24 VDC power input Voltage 24 V DC 10 Typical current consumption 250 mA without optional modules Maximum current consumption 1200 mA with optional modules inserted The terminals on the RMIO board as well as on the optional modules attachable to the board fulfil the Protective Extra Low Voltage PELV requirements stated in EN 50178 provided that the external circuits connected to the terminals also fulfil the requirements and the installation site is below 2000 m 6562 ft Above 2000 m 6562 ft see page 49 Motor control and I O board RMIO Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 78 Isolation and grounding diagram Test voltage 500 V AC
133. ss the shroud onto the terminals View of cable terminal installation Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 62 Connecting the control cables Lead the cable through the control cable entry 1 Connect the control cables as described below Connect the conductors to the appropriate detachable terminals of the RMIO board refer to chapter Motor control and I O board RMIO Tighten the screws to secure the connection Terminals Frame sizes R2 to R4 The control cable connection terminals are exposed when the control panel mounting platform is turned aside by pulling this knob Be careful do not use excess force when pulling Detachable connection terminals pull up X39 for control panel cable Terminal for optional Optional module 1 Prevention of Unexpected Start Optional module 2 I O cables Ground the control cable shields in the holes with screws See section 360 degrees grounding DDCS communication option module 3 RDCO Place the warning sticker here Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 63 Frame sizes R5 and R6 1 View of frame size R6 i y f 1 Control panel 3 Optional module 2 Optional module 1 DDCS communication option mo
134. stems only Frame size RG The drive is eguipped with EMC filter E210 The filter is suitable for TN earthed and IT unearthed systems 2 The motor and control cables are selected as specified in the Hardware Manual 3 The drive is installed according to the instructions given in the Hardware Manual 4 Maximum cable length is 100 metres WARNING A drive of category C3 is not intended to be used on a low voltage public network which supplies domestic premises Radio frequency interference is expected if the drive is used on such a network Second environment drive of category C4 If the provisions under Second environment drive of category C3 cannot be met e g the drive cannot be equipped with EMC filter E200 when installed to an IT unearthed network the requirements of the standard can be met as follows for restricted distribution 1 Itis ensured that no excessive emission is propagated to neighbouring low voltage networks In some cases the inherent suppression in transformers and cables is sufficient If in doubt a supply transformer with static screening between the primary and secondary windings can be used Medium voltage network Supply transformer pi poeti el P cem s odd Rd 1 Neighbouring network SE st lic scien Point of measurement Low voltage Low voltage Equipment victim Equipment Equipment L el ds zi
135. t capacitors once a year according to ACS 600 800 Capacitor Reforming Guide code 64059629 Maintenance Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 87 LEDs This table describes LEDs of the drive Where LED When the LED is lit RMIO board Red Drive in fault state Green The power supply on the board is OK Control panel mounting platform Red Drive in fault state T i with type code selection 20400 Green The main 24 V power supply for the control panel and the only RMIO board is OK The LEDs are not visible in frame sizes R2 to R6 Maintenance Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 88 Maintenance Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 89 Technical data What this chapter contains This chapter contains the technical specifications of the drive e g the ratings sizes and technical reguirements provisions for fulfilling the reguirements for CE and other markings and warranty policy IEC data Ratings The IEC ratings for the ACS800 01 with 50 Hz and 60 Hz supplies are given below The symbols are described below the table ACS800 01 size Nominal No Light overload Heavy duty use Frame Air flow Heat ratings odc use size dissipation lcontmax Imax Peontmax Lon PN land
136. ta Select the cables Y Unpack and check the units Check that all necessary optional modules and equipment are present and correct Only intact units may be started up Y If the drive is about to be connected to an IT ungrounded system check that the drive is not equipped with EMC filtering intended for grounded systems Check the installation site Y Install the drive on a wall or in a cabinet Y Route the cables 21 See Technical data IEC data or NEMA data Technical data Planning the electrical installation For compliance with the European Union EMC Directive see Technical data CE marking Option manual if optional equipment is included Mechanical installation Unpacking the unit If the converter has been non operational for more than one year the converter DC link capacitors need to be reformed Ask ABB for instructions The ACS800 01 U1 Type code For instructions on how to disconnect the EMC filtering contact ABB Mechanical installation Before installation Technical data Mechanical installation Planning the electrical installation Routing the cables For compliance with the European Union EMC Directive see Technical data CE marking About this manual Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 22 Task Check the insulation of the motor and the motor cable
137. tems Part 3 EMC requirements and specific test methods mandated by the Trans Tasman Electromagnetic Compatibility Scheme Definitions EMC stands for Electromagnetic Compatibility It is the ability of electrical electronic equipment to operate without problems within an electromagnetic environment Likewise the equipment must not disturb or interfere with any other product or system within its locality The Trans Tasman Electromagnetic Compatibility Scheme EMCS was introduced by the Australian Communication Authority ACA and the Radio Spectrum Management Group RSM of the New Zealand Ministry of Economic Development NZMED in November 2001 The aim of the scheme is to protect the radiofrequency spectrum by introducing technical limits for emission from electrical electronic products First environment includes establishments connected to a low voltage network which supplies buildings used for domestic purposes Second environment includes establishments connected to a network not supplying domestic premises Drive of category C2 drive of rated voltage less than 1000 V and intended to be installed and commissioned only by a professional when used in the first environment Note A professional is a person or organisation having necessary skills in installing and or commissioning power drive systems including their EMC aspects Drive of category C3 drive of rated voltage less than 1000 V and intended for use in the second environme
138. the PE conductors of the input and motor cables to the grounding terminal Note cable lugs are needed in frame sizes R2 and R3 Connect the separate PE conductor if used to the grounding terminal Connect the phase conductors of the input cable to the U1 V1 and W1 terminals and the phase conductors of the motor cable to the U2 V2 and W2 terminals For frame size R6 see Wall installed units European version figures for frame size R6 In case of a cable lug installation use UL listed cable lugs and tools given below or corresponding to meet UL requirements Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 99 8 Tighten the clamping nuts of the cable glands After connecting the control cables fasten the front covers Warning sticker Wire size Compression lug Crimping tool MCM AWG Manufacturer Type Manufacturer Type No of crimps 6 Burndy YAV6C L2 Burndy MY29 3 sco CCL 6 38 Isco LC 10 2 4 Burndy YA4C L4BOX Burndy MY29 3 sco CCL 4 38 Isco MT 25 2 Burndy YA2C L4BOX Burndy MY29 3 2 sco CRC 2 Isco DT 12 sco CCL 2 38 Isco MT 25 1 Burndy YA1C L4BOX Burndy MY29 3 2 sco CRA 1 38 Isco DT 12 sco CCL 1 38 Isco MT 25 Thomas amp Betts 54148 Thomas amp Betts TBM 8 3 1 0 Burndy YA25 L4BOX Burndy MY29 3 2 sco CRB 0 Isco DT 12 sco CCL 1 0 38 Isco MT 25 Tho
139. the best alternative for low voltage digital signals but single shielded twisted pair cable Figure b is also usable A double shielded twisted A single shielded twisted pair cable pair cable Run analogue and digital signals in separate shielded cables Relay controlled signals providing their voltage does not exceed 48 V can be run in the same cables as digital input signals It is recommended that the relay controlled signals be run as twisted pairs Never mix 24 V DC and 115 230 V AC signals in the same cable Relay cable The cable type with braided metallic screen e g OLFLEX by LAPPKABEL Germany has been tested and approved by ABB Control panel cable In remote use the cable connecting the control panel to the drive must not exceed 3 metres 10 ft The cable type tested and approved by ABB is used in control panel option kits Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 49 Connection of a motor temperature sensor to the drive I O and the surface of accessible parts of electrical eguipment which are either non A WARNING IEC 60664 requires double or reinforced insulation between live parts conductive or conductive but not connected to the protective earth To fulfil this requirement the connection of a thermistor and other similar components to the digital inputs of the drive can be implemented
140. tion of Unexpected Start Q950 Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 73 Motor control and I O board RMIO What this chapter contains This chapter shows external control connections to the RMIO board for the ACS800 Standard Control Program Factory Macro specifications of the inputs and outputs of the board Note on terminal labelling Optional modules Rxxx may have identical terminal designations with the RMIO board Note on external power supply External 24 V power supply for the RMIO board is recommended if the application requires a fast start after connecting the input power supply fieldbus communication is required when the input power supply is disconnected The RMIO board can be supplied from an external power source via terminal X23 or X34 or via both X23 and X34 The internal power supply to terminal X34 can be left connected when using terminal X23 terminal X34 the loose end of the cable removed from the RMIO board terminal must be secured mechanically to a location where it cannot come into contact with electrical parts If the screw terminal plug of the cable is removed the wire ends must be individually insulated A WARNING If the RMIO board is supplied from an external power source via Parameter settings In Standard Control Program set parameter 16 9 CTRL BOARD SUPPLY to EXTERNAL 24V if the RMIO board is powered from an external suppl
141. unction does not disconnect the voltage of the main and auxiliary circuits from the drive Therefore maintenance work on electrical parts of the drive or the motor can only be carried out after isolating the drive system from the main supply Note If a running drive is stopped by using the Prevention of Unexpected Start function the drive will cut off the motor supply voltage and the motor will coast to stop Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 43 Selecting the power cables General rules Dimension the mains input power and motor cables according to local regulations The cable must be able to carry the drive load current See chapter Technical data for the rated currents The cable must be rated for at least 70 C maximum permissible temperature of conductor in continuous use For US see Additional US requirements The inductance and impedance of the PE conductor cable grounding wire must be rated according to permissible touch voltage appearing under fault conditions so that the fault point voltage will not rise excessively when a ground fault occurs 600 VAC cable is accepted for up to 500 V AC 750 V AC cable is accepted for up to 600 V AC For 690 V AC rated equipment the rated voltage between the conductors of the cable should be at least 1 kV For drive frame size R5 and larger or motors larger than 30 kW 40
142. unit Y WARNING If a drive with EMC filter selection E202 or E200 is installed on an IT Electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 93 Connecting the power cables Diagram Drive INPUT UDC UDC I OUTPUT PE ui vi w1 Gin R MSZ 2 p 3 ul osla a ET Ld E qb Hp l I 3 T 4 i PE PE PE FE For alternatives see Br Exteel brake resistor Planning the electrical a ERE installation A i Disconnecting device disconnecting means L1 L2 L3 1 2 Grounding of the motor cable shield at the motor end If shielded cable is used not reguired but For minimum radio freguency interference recommended use a separate PE cable 1 or a ground the cable shield 360 degrees at the lead through of cable with a grounding conductor 2 if the the motor terminal box conductivity of the input cable shield is lt 50 of the conductivity of the phase conductor n Ground the other end of the input cable shield or PE conductor at the distribution board 3 360 degrees grounding recommended if shielded Y 360 degrees grounding cable 4 360 degrees grounding required Conductive gaskets or ground the cable by twisting the shield as follows W flattened width gt 1 5 length Ke el 5 Use a separate grounding cable if the conductivity of the cable shield
143. ury or death or Only qualified electricians are allowed to install and maintain the drive Never work on the drive motor cable or motor when main power is applied After disconnecting the input power always wait for 5 min to let the intermediate circuit capacitors discharge before you start working on the drive motor or motor cable Always ensure by measuring with a multimeter impedance at least 1 Mohm that 1 voltage between drive input phases U1 V1 and W1 and the frame is close to 0 V 2 voltage between terminals UDC and UDC and the frame is close to 0 V Do not work on the control cables when power is applied to the drive or to the external control circuits Externally supplied control circuits may cause dangerous voltages inside the drive even when the main power on the drive is switched off Do not make any insulation or voltage withstand tests on the drive or drive modules When reconnecting the motor cable always check that the phase order is correct Note The motor cable terminals on the drive are at a dangerously high voltage when the input power is on regardless of whether the motor is running or not The brake control terminals UDC UDC R and R terminals carry a dangerous DC voltage over 500 V Depending on the external wiring dangerous voltages 115 V 220 V or 230 V may be present on the terminals of relay outputs RO1 to RO3 or on the optional AGPS board Prevention of Unexpected Start AC
144. w clrwtr com Email info clrwtr com 80 Installation checklist Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 81 Maintenance What this chapter contains This chapter contains preventive maintenance instructions Safety WARNING Read the Safety instructions on the first pages of this manual before performing any maintenance on the equipment Ignoring the safety instructions can cause injury or death Maintenance intervals If installed in an appropriate environment the drive requires very little maintenance This table lists the routine maintenance intervals recommended by ABB Maintenance Interval Instruction Capacitor reforming Every year when stored See Reforming Heatsink temperature check and cleaning Depends on the dustiness of the environment every 6 to 12 months See Heatsink Cooling fan change Every six years See Fan Change of additional cooling fan in IP 55 units and in IP 21 units when included Every three years See Additional fan Frame size R4 and up capacitor change Every ten years See Capacitors Maintenance Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 82 Heatsink The heatsink fins pick up dust from the cooling air The drive runs into overtemperature warnings and faults if the heatsink is not clean In a normal enviro
145. wed bend radius is 35 mm 1 4 in Safety instructions Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 10 Operation These warnings are intended for all who plan the operation of the drive or operate the drive WARNING Ignoring the following instructions can cause physical injury or death or damage to the equipment e Before adjusting the drive and putting it into service make sure that the motor and all driven equipment are suitable for operation throughout the speed range provided by the drive The drive can be adjusted to operate the motor at speeds above and below the speed provided by connecting the motor directly to the power line e Donotactivate automatic fault reset functions of the Standard Control Program if dangerous situations can occur When activated these functions will reset the drive and resume operation after a fault e Do not control the motor with the disconnecting device disconnecting means instead use the control panel keys and or commands via the I O board of the drive The maximum allowed number of charging cycles of the DC capacitors i e power ups by applying power is five in ten minutes Note e lf an external source for start command is selected and it is ON the drive with Standard Control Program will start immediately after fault reset unless the drive is configured for 3 wire a pulse start stop e When the control location is
146. with a sine filter The peak phase to phase voltage with the sine filter is approximately 1 5 x Uy Note 10 Common mode filter is available as a plus code option E208 or as a separate kit one box including three rings for one cable Permanent magnet synchronous motor Only one permanent magnet motor can be connected to the inverter output It is recommended to install a safety switch between the permanent magnet synchronous motor and the drive output The switch is needed to isolate the motor during any maintenance work on the drive Planning the electrical installation Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 39 Supply connection Disconnecting device disconnecting means Install a hand operated input disconnecting device disconnecting means between the AC power source and the drive The disconnecting device must be of a type that can be locked to the open position for installation and maintenance work EU To meet the European Union Directives according to standard EN 60204 1 Safety of Machinery the disconnecting device must be one of the following types switch disconnector of utilization category AC 23B EN 60947 3 disconnector that has an auxiliary contact that in all cases causes switching devices to break the load circuit before the opening of the main contacts of the disconnector EN 60947 3 circuit breaker suitable for isolation in accordance with E
147. y Motor control and I O board RMIO Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 74 External control connections non US External control cable connections to the RMIO board for the ACS800 Standard Control Program Factory Macro are shown below For external control connections of other control macros and programs see the appropriate Firmware Manual X2 RMIO X20 X20 RMIO 1 1 VREF Reference voltage 10 V DC 1 kohm lt R Terminal block size 2 12 AGND lt 10 kohm cables 0 3 to 3 3 mm 22 to 12 AWG X21 X21 Tightening torgue 11 41 VREF Reference voltage 10 V DC 1 kohm lt Ri lt 0 2 to 0 4 Nm 7 12 42 AGND 10 kohm 0 2 to 0 3 Ibf ft 3 13 A Speed reference O 2 10 V Rin 1 14 14 AM 200 kohm 15 lb d Al2 By default not in use 0 4 20 mA Rin 6 16 Al2 100 ohm 7 Sa AI3 By default not in use 0 4 20 MA Rin 8 18 AI3 100 ohm ren 9 F 19 AO1 Motor speed 0 4 20 mA 2 0 motor nom 10 410 AO1 speed R lt 700 ohm 11 111 AO2 Output current 0 4 20 mA 2 0 motor 11112 7112 AO2 nom current RL lt 700 ohm optional terminal block in ACS800 02 X
148. y Lift the drive by the lifting lugs only Do not tilt the unit The unit will overturn from a tilt of about 6 degrees Use extreme caution when manoeuvring a drive that runs on wheels An overturning unit can cause physical injury Do not tilt semiconductors remain hot for a while after disconnection of the electrical supply e Make sure that dust from borings and grindings does not enter the drive when installing Electrically conductive dust inside the unit may cause damage or malfunctioning e Beware of hot surfaces Some parts such as heatsinks of power e Ensure sufficient cooling e Donotfasten the drive by riveting or welding Safety instructions Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com Printed circuit boards y WARNING Ignoring the following instructions can cause damage to the printed circuit boards A e The printed circuit boards contain components sensitive to electrostatic discharge Wear a grounding wrist band when handling the boards Do not touch the boards unnecessarily Fibre optic cables WARNING Ignoring the following instructions can cause equipment malfunction and damage to the fibre optic cables e Handle the fibre optic cables with care When unplugging optic cables always grab the connector not the cable itself Do not touch the ends of the fibres with bare hands as the fibre is extremely sensitive to dirt The minimum allo
149. yu yrn nme ote ia OR Faroe ne E RR EROR DG nan pin 59 Cabinet installation IP 21 UL type 11 RII II 59 Frame size RO ua gw ae iwa adhesives eese s cu de ke Nur pe et 60 Erame size R6 sau card AAA nave DASA TIAS QE I 61 Connecting the control cables 000 ccc ere 62 Terminals s am ertet cem eh mr Rc Re pr loco T ee Si a iat Qe A 62 360 degrees grounding 0 0200 nh 64 When the outer surface of the shield is covered with non conductive material 64 Connecting the shield wires ee 64 Cabling of I O and fieldbus modules ee 65 Pulse encoder module cabling 0 cee eens 65 Fastening the control cables and covers 0 00 cee eee eee eee 66 Installation of optional modules and PC 66 Fibre Optic link a Yd edyn es ota aed east Cae RR E REIN UM 66 Installation of AGPS board Prevention of Unexpected Start Q950 What this chapter contains 0 0 RR RR ee 67 Prevention of Unexpected Start Q950 0 cee 67 Installation of the AGPS board Y FF FFF re 67 Circuit diagram zz air lan dale cope A wht AK ho a weed sq EI kak RE 69 Dimensional drawing 5 iet ee ei BAW Mn ee eed 70 AGPS 11C board specifications 00 0c ttt teen eee 71 Motor control and I O board RMIO Table of contents Phone 800 894 0412 Fax 888 723 4773 Web www clrwtr com Email info clrwtr com 16 What this chapter contains i eu SR K STA Ee ee A CREER 73 Note on

ABB ACS800-01 & ACS800-U1 Drives Hardware Manual

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ABB ACS800-01 &amp; ACS800-U1 Drives Hardware Manual

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ABB ACS800-01 & ACS800-U1 Drives Hardware Manual