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ABB ACS800 Manual(4)

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1. x2 RMIO RMIO X20 X20 Terminal block size 1 11 VREF Reference voltage 10 VDC 1 kohm R lt cables 0 3 to 3 3 mm 22 to 12 AWG 2 12 AGND 10 kohm Tightening torque RT Ael 0 2 to 0 4 Nm 0 2 to 0 3 Ibf ft r11 31 VREF Reference voltage 10 VDC 1 kohm lt R lt 7 m2 12 AGND 10 kohm 3 13 Al1 Speed reference 0 2 10 V Rin gt J l4 14 AI1 200 kohm 5 15 Al2 By default not in use 0 4 20 mA Rin 6 16 Al2 100 ohm 7 7 Al3 By default not in use 0 4 20 mA Rin 8 18 AI3 100 ohm on 19 AO1 Motor speed 0 4 20 mA O motor nom 10 10 AO1 speed R lt 700 ohm 11 111 AO2 Output current 0 4 20 mA O motor 9 12 112 AO2 nom current R lt 700 ohm X22 X22 o1 1 Jona Start r l 9 Lo 2 12 DI2 Stop 1 optional terminal block in ACS800 U2 3 13 DI3 Forward Reverse 1 idas 4 14 DI4 Acceleration amp deceleration select 2 1 Only effective if par 10 03 is set to A 5 15 DI5 Constant speed select 3 REQUEST by the user 1e 16 DI6 Constant speed select 9 se E 7 17 24VD 24 VDC max 100 mA open 1 closed lg Tg 24VD DI4 Ramp times according to 9 19 DGND1 Digital ground O parameters 22 02 and 22 03 10 10 DGND2 Digital ground 2 Duane Tee ORTU LEN 11 111 DIIL Start interlock O stop 3 See par group 12 CONSTANT X23 nee SPEE
2. 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 11 0030 5 The optional selections are given thereafter separated by plus 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 11 regenerative wall mounted When no options are selected IP 21 Control Panel CDP312R DDCS communication option module RDCO 03 no EMC filter Standard Application Program cable connection box cabling from below boards with coating one set of manuals U11 wall mounted USA When no options are selected UL type 1 Control Panel CDP312R DDCS communication option module RDCO 03 no EMC filter US version of the Standard Application Program three wire start stop as default setting US gland conduit plate boards with coating one set of English manuals Size Refer to Technical data IEC ratings Voltage range 2 208 220 230 240 VAC nominal rating in bold 3 380 400 415 VAC 5 380 400 415 440 460 480 500 VAC 7 525 575 600 690 VAC options Filter E200 EMC RFI filter for second environment TN grounded system unrestricted distribution E202 EMC RFI filter for first environment TN gr
3. RMIO Relay outputs Varistor X25 L 1 ROL a 230 VAC 2 ROT o 3 RO1 RC filter x26 HIC J 1 RO2 A e 230 VAC 2 ROA 3 RO2 mE Diode X27 1 RO3 2 RO3 24 VDC H o 3 RO3 Planning the electrical installation 54 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 the best alternative for low voltage digital signals but single shielded twisted pair cable Figure b is also usable 4 mud eae a b 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 VDC and 115 230 VAC 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
4. External 24 V power supply for the RMIO boards via terminal X34 124 External 24 V power supply for the RMIO boards via terminal X34 AA EP ED P EP IP 3AFE68367883 Rev B EN EFFECTIVE 5 5 2006 ABB Oy AC Drives P O Box 184 FI 00381 HELSINKI FINLAND Telephone 358 10 22 11 Fax 358 10 22 22681 Internet http www abb com ABB Inc Automation Technologies Drives Motors 16250 West Glendale Drive New Berlin WI 53151 USA Telephone 262 785 3200 800 HELP 365 Fax 262 780 5135
5. 87 ACS800 11 U11 specific parameters in the application program lille 88 Terms drd abDrevidlialis i Ree eoo ti tent E T ac ue CE ord 88 Actual signals and parameters of the line converter in the motor side converter control program 89 OS ACTUAL SIGNALS qutt oh bet V eO RE SAA 89 95 HARDWARE SPECIF Loi tbe ote debeo ER cera rtt aos WAR o qtiod 89 Fieldbus control interface o o o o o oo rrr 90 Block diagram reference select llle 90 Connection diagram of the RMIO board in the line side converter 2 0005 91 Fault tracing 9 Cogo duce zoe A p ehe CR PR OR RN odd e ede De dor E Rd REO De 92 Fault Same ID numbers l l 92 Changing the control panel to the line side converter 20 0 cc cece eee eee 92 Changing the control panel to the motor side converter ooooooccoccoooro 93 Table of contents 17 Maintenance Whatithis Chapter contains osse irate ose thet SD A E ha ee Me ee n Et 95 Safety 24 seta sa garded aden de Ph base Oe aa Tae a AG A eM SE OURS a ES 95 Maintenance IMENS dis eevee a Ie a e Ro Bec ed ted Cobh awe e hee E rh cia 95 Heatsink a Pia n ERR qa wee E EAR EA 96 Main cooling TAM iz due AA ob Geo nep AA E NE Ede Fabia t deg 96 Fan replacement R5 R6 ws es eser es Rex Su o Rem oet BS er es uad a 97 ps A O E E a 97 Replacement R5 van cor a CC RAS eae 97 Replacement RO encino dl s AER Cd cte o m eor d e Re eared cli 98
6. 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 Note Two RDCO modules are provided for the DDCS fibre optic link between the RMIO boards of the line side and motor side converters Channel CHO of the RDCO 03 module in the line side converter and channel CH1 of the RDCO module in the motor side converter are used for the internal communication In case multiple devices are to be connected to one channel they must be connected in a ring Electrical installation 69 Installation of AGPS board Prevention of Unexpected Start Q950 What this chapter contains This chapter describes electrical installation of the optional Prevention of Unexpected 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 Planning the electrical installation page 37 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 instr
7. Equipment Equipment 2 The drive is installed according to the instructions given in the Hardware Manual 3 The motor and control cables used are selected as specified in the Hardware Manual Equipment warranty and liability The manufacturer warrants the equipment supplied against defects in design materials and workmanship for a period of twelve 12 months after installation or twenty four 24 months from date of manufacturing whichever first occurs The local ABB office or distributor may grant a warranty period different to the above and refer to local terms of liability as defined in the supply contract The manufacturer is not responsible for any costs resulting from a failure if the installation commissioning repair alternation or ambient conditions of the drive do not fulfil the requirements specified in the documentation delivered with the unit and other relevant documentation units subjected to misuse negligence or accident units comprised of materials provided or designs stipulated by the purchaser In no event shall the manufacturer its suppliers or subcontractors be liable for special indirect 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 limit
8. Remove the clear plastic shroud as shown in section Power cable installation procedure on page 60 10 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 See Wall installed units European version for cabling figures In case of a cable lug installation use UL listed cable lugs and tools given below or corresponding to meet UL requirements Electrical installation 64 Wire size Compression lug Crimping tool kcmil AWG Manufacturer Type Manufacturer Type No of crimps 4 Burndy YA4C L4BOX Burndy MY29 3 1 llsco CCL 4 38 llsco MT 25 1 2 Burndy YA2C L4BOX Burndy MY29 3 2 llsco CRC 2 llsco IDT 12 1 llsco CCL 2 38 llsco MT 25 1 1 Burndy YA1C L4BOX Burndy MY29 3 2 llsco CRA 1 38 llsco IDT 12 1 llsco CCL 1 38 llsco MT 25 1 Thomas amp Betts 54148 Thomas Betts TBM 8 3 1 0 Burndy YA25 L4BOX Burndy MY29 3 2 llsco CRB 0 llsco IDT 12 1 llsco CCL 1 0 38 llsco MT 25 1 Thomas amp Betts 54109 Thomas Betts TBM 8 3 2 0 Burndy YAL26T38 Burndy MY29 3 2 llsco CRA 2 0 llsco IDT 12 1 llsco CCL 2 0 38 llsco MT 25 1 Thomas amp Betts 54110 Thomas Betts TBM 8 3 11 Tighten the clamping nuts of the cable glands After connecting the control cables fasten the clear plastic shroud and front covers Warning sticker There are warning stickers in different
9. The optional Safe torque off function includes an ASTO board which is connected to the drive and an external power supply See also chapter Planning the electrical installation page 37 Installation of the ASTO board A Update Notice WARNING Dangerous voltages can be present at the ASTO board even when the 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 See page 24 for location of terminal block X41 of the drive page 6 in this Update Notice for the circuit diagram page 6 in this Update Notice for the dimensions of the ASTO 11C board page 6 in this Update Notice for the technical 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 ter
10. Tightening torque 0 2 to 0 4 Nm 2 to 4 Ibf in 1 non programmable I O 2 External earth ground fault indication via digital input DI4 See parameter 30 04 EXT EARTH FAULT 3 External alarm fault indication via digital input DI5 See parameter 30 05 EXT EVENT 4 START command via digital input DI7 See parameter 16 01 RUN BIT SEL X20 1 VREF Reference voltage 10 VDC 2 GND 1 kohm R lt 10 kohm X21 1 VREF Reference voltage 10 VDC 2 GND 1 kohm R lt 10 kohm 3 Al1 By default not in use 0 2 10 V 4 Al1 Rin gt 200 kohm 5 Al2 By default not in use 0 4 20 mA 6 Al2 Rin 100 ohm 7 Al3 By default not in use 0 4 20 mA 8 AI2 Rin 100 ohm 9 AO1 By default not in use 0 4 20 mA 10 AO1 R lt 700 ohm 11 AO2 By default not in use 0 4 20 mA 12 AO2 R 700 ohm X22 1 DI1 Acknowledgement of converter fan 1 2 DI2 Stop Start 3 DI3 Acknowledgement from main contactor 1 4 DI4 By default not in use 2 5 DI5 By default not in use 3 6 DI6 By default not in use 7 24V 24 VDC max 100 mA 8 24V 9 DGND Digital ground 10 DGND Digital ground 11 DI7 DIIL By default not in use X23 1 24V Auxiliary voltage output and input non 2 GND isolated 24 VDC 250 mA X25 1 RO11 Relay output 1 By default not in
11. o o o oo eens 76 Parameler setings ts e M CES EI et LI Don Ete d dre cdi uos IDE 76 External control connections Non US 00 eee 77 External control connections US aas aa aaaea 78 RMIO Board specificallgfis lt 2 oi Cee eine DERE Peur a aa AAA ewe 79 Adialogue INPUTS 24 o5 tal La e a do a a Bs a Vr CE hie oh eG a ah teat od 79 Constant voltage output 2 0 eee eee ees 79 Auxiliary power output 6 0 RR RR Re e e e e e e 3e es 79 Analogue outputs eR aa aaa 79 Digital Inpuls acies dee AA A EAE RP RUE M ei eRe ER Oke E 79 Relay outputs ix dex ka e ec Ed REUS DA hatha aa ACT eae ad 80 DDCS fibr amp optic link 2 dono one co heh ek etc ede ost Ur Rs rd e S e Rd n 80 24 VDC POWER PUE asis al a CT REX WENNS C NE R CREDO SENE AE DECRE 80 Installation checklist e 260 24 6E E CXELEDIAERESS SATA MM DUE PR E ES 83 Operation What this chapter contalns sce mue e ooo coe ex ele So Oe Boe CH E NOU ER he Peas Ae 85 Starb pcand use A A Ages qn ed ee me d oco eds PR d dex 85 ACS800 11 U11 specific parameters in the IGBT Supply Control Program 86 Terms and abbreviations 4 dea ERU ye re eroe CORR REOR Eis ICI ue END e tee Rod E 86 Parameters ioo ee uem pue ehe E ed wr Edere eter der voe deny hog ted 86 16 SSTEMCTRINPUTS as bacs MEA Iter es a FE e has Ebo MD ud 86 31 AUTOMATIC RESET Lu e prada Sra deve tah eee dx Re ee oco s ew Rs 86 Fixed parameters with the ACS800 11 ACS800 U11 and ACS800 17
12. 2 RO12 use 3 RO13 X26 1 RO21 Relay output 2 By default not in 2 RO22 LA use 3 RO23 X27 1 RO31 Relay output 3 Main contactor 2 RO32 I control 2 3 RO33 24 VDC Operation 92 Fault tracing Flashing messages WARNING ID 2 or FAULT ID 2 on the control panel display indicate a warning or fault state in the line side converter when the control panel controls the motor side converter FAULT ID 2 ACS 800 0050_5MR kkk FAULT kkk LINE CONV FF51 To display the warning or fault identification text shift the control panel to view the line side converter as described in section Changing the control panel to the line side converter Fault Same ID numbers If the ID numbers of the line side and the motor side converters are set equal the control panel stops functioning To clear the situation Disconnect the panel cable from the RMIO board of motor side converter Set the ID number of the line side converter RMIO board to 2 For the setting procedure see the application program firmware manual e Connect the disconnected cable to the RMIO board of the motor side converter again and set the ID number to 1 Changing the control panel to the line side converter Step Action Press key Display example 1 To enter the Drive Selection Mode Note In local control mode the motor side converter trips ACS 800 0050 5MR if parameter 30 02 PANEL LOSS is set to FAULT Refer to th
13. Operation 89 Actual signals and parameters of the line converter in the motor side converter control program No Name Value Description FbEq Def 09 ACTUAL SIGNALS Signals from the line converter 09 12 LCU ACT SIGNAL 1 09 13 LCU ACT SIGNAL 2 Line converter signal selected by par 95 08 LCU PAR1 SEL Line converter signal selected by par 95 09 LCU PAR2 SEL eje ufo 95 HARDWARE SPECIF Line converter references and actual signal selections 95 06 LCU Q POW REF Reactive power reference for the line converter i e the value for par 24 02 Q POWER REF2 in the IGBT Supply Control Program Scaling example 1 10000 equals to a value of 10000 of parameter 24 02 Q POWER REF2 and 100 of par 24 01 Q POWER REF i e 100 of the converter nominal power given in par 04 06 CONV NOM POWER when par 24 03 Q POWER REF2 SEL is set to PERCENT Scaling example 2 Par 24 03 Q POWER REF2 SEL is set to kVAr A value of 1000 of par 95 06 equals to 1000 kVAr of par 24 02 Q POWER REF2 Value of par 24 01 Q POWER REF is then 100 1000 kVAr divided by converter nominal power in kVAr Scaling example 3 Par 24 03 Q POWER REF2 SEL is set to PHI A value of 10000 of par 95 06 equals to a value of 100 deg of parameter 24 02 Q POWER REF2 which is limited to 30 deg The value of par 24 01 Q POWER REF will be determined approximately according to the following equation where P is read from actual signal 1 06 P
14. The line side and motor side converters consist of six insulated gate bipolar transistors with free wheeling diodes The converters have their own control programs The parameters of both programs can be viewed and changed using one control panel The control panel can be switched between the converters as described in chapter Operation Line side converter The IGBT supply module rectifies three phase AC current to direct current for the intermediate DC link of the drive The intermediate DC link is further supplying the motor side converter that runs the motor The line filter suppresses the AC voltage and current harmonics The IGBT supply module is a four quadrant switching mode converter i e the power flow through the converter is reversible By default the converter controls the DC link voltage to the peak value of the line to line voltage The DC voltage reference can be set also higher by a parameter The control of the IGBT power semiconductors is based on the Direct Torque Control DTC method also used in the motor control of the drive Two line currents and the DC link voltage are measured and used for the control The ACS800 11 U11 26 AC voltage and current waveforms The AC current is sinusoidal at a unity power factor The IGBT supply unit does not generate characteristic current or voltage overtones like a traditional 6 or 12 pulse bridge does The Total Harmonic Distortion THD in current is given in chapter Techn
15. 13 Table of contents ACS800 Single Drive Manuals 000 00 eens 2 Safety instructions Whatthis Chapter Contains s vesc obs e ACE t A A MEL ee eee Eur 5 To which products this chapter applies 0 0000 ccc nh 5 Use of Walnings and Notes cubito cbr os aut mS tinens e ao RIDES ES REQUE S arie Ria dE 5 Installation and maintenance work o 6 COELOUTIGIFIQ e p Siete ele m Ordo esce re ES M eee EE E Eure otek dde ond etel dte te 7 Mechanical installation and maintenance o o o ooooooooo ere 8 Printed circuit DOards pcg s er Sue eter Has wh ee m AGIR Free e Tus e Secr escam oh EP Rar ge 9 Fibre optic cables o ooooooooror hr rrr rr rn 9 Op ration eso edes Weed aca a Eu avis wae onde s ace eH Gon SIE wie had d os 10 Permanent Magnet Moto iube A Fue S4 EA 11 Installation and maintenance work o 11 Startup abd opelatiortu eu ns heise S er p a S eta ev EE EIS PIE S 11 Table of contents About this manual What this chapter contains 2 5 Elek XG GG A RE AA GR GRE EE 19 Hritendetd a dience sesos goo Kits o HR A al eat aed Sk ahs amp Dor den E d p ong RU RARE 19 Other related mahu als ix ores xc a ad yee GRE RR as 19 Common chapters Tor several products 12x esse ds eR PEE bb oes Ss 20 Categorization according to the frame size llle 20 Categorization according to the plus code 0 cece ees 20 Content aio ss eee ee ne eR e reU GR LECHE RENE Dx e Mic ctt DOR Bete RU 20 Installation
16. 67 80 34500 500 ABB Control OFAF000H80 000 0050 3 80 100 63600 500 ABB Control OFAF000H100 000 0060 3 112 125 103000 500 ABB Control OFAF00H125 00 0070 3 140 160 200000 500 ABB Control OFAF00H160 00 0100 3 153 200 350000 500 ABB Control OFAF1H200 1 Three phase supply voltage 380 V 400 V 415 V 440 V 460 V 480 V or 500 V 0020 5 29 40 9140 500 ABB Control OFAF000H40 000 0025 5 33 40 9140 500 ABB Control OFAF000H40 000 0030 5 44 50 15400 500 ABB Control OFAF000H50 000 0040 5 54 63 21300 500 ABB Control OFAF000H63 000 0050 5 65 80 34500 500 ABB Control OFAF000H80 000 0060 5 76 100 63600 500 ABB Control OFAF000H100 000 0070 5 112 125 103000 500 ABB Control OFAF00H125 00 0100 5 129 160 200000 500 ABB Control OFAF00H160 00 0120 5 145 200 350000 500 ABB Control OFAF1H200 1 Three phase supply voltage 525 V 550 V 575 V 600 V 660 V or 690 V 0060 7 53 63 28600 690 ABB Control OFAA0GG63 0 0070 7 73 80 52200 690 ABB Control OFAA0GG80 0 0100 7 86 100 93000 690 ABB Control OFAA1GG100 1 maximum total t value for 550 V PDM code 00184674 H Technical data 102 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 2 2001 For other conditions size the cables according to local safety regulations appropriate in
17. 88 75 71 55 R6 405 2800 PDM code 00184674 H Technical data 100 Symbols Nominal ratings leontmax Continuous rms output current No overload capability at 40 C Imax maximum output current Available for 10 s at start otherwise as long as allowed by drive temperature Typical ratings No overload use Pcontmax typical motor power The power ratings apply to most IEC 34 motors at the nominal voltage 230 V 400 V 500 V or 690 V Light overload use 10 overload capability lon continuous rms current 10 overload is allowed for one minute every 5 minutes Py typical motor power The power ratings apply to most IEC 34 motors at the nominal voltage 230 V 400 V 500 V or 690 V Heavy duty use 50 overload capability long continuous rms current 50 96 overload is allowed for one minute every 5 minutes Pha typical motor power The power ratings apply to most IEC 34 motors at the nominal voltage 230 V 400 V 500 V or 690 V Sizing 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 momentary motor shaft power is limited to approximately 1 3 Peont max If the limit is exceeded motor torque and current are automatically restricted The function protects the input bridge and LCL filter of the drive ag
18. AGPS 11C board specifications Nominal input voltage 115 230 VAC 10 Nominal input current 0 1 A 230 V 0 2 A 115 V Nominal frequency 50 60 Hz Max external fuse 16A X1 terminal sizes 3 x 2 5 mm Output voltage 15 VDC 0 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 Weight x Depth Weight with enclosure 0 75 kg Approvals C UL US listed Installation of AGPS board Prevention of Unexpected Start Q950 74 Installation of AGPS board Prevention of Unexpected Start Q950 75 Motor control and I O board RMIO What this chapter contains This chapter shows e external control connections to the RMIO board for the ACS800 Standard Application Program Factory Macro specifications of the inputs and outputs of the board To which products this chapter applies This chapter applies to ACS800 units which employ RMIO 01 board from revision J onwards and RMIO 02 board from revision H onwards Note for the ACS800 02 with enclosure extension and the ACS800 07 The connections for the RMIO board shown below apply also to optional terminal block X2 available for the ACS800 02 and ACS800 07 The terminals of the RMIO board are wired to terminal block X2 internally Terminals of X2 accept cables from 0 5 to 4 0 mm 22 to 12 AWG Tightening torque for screw t
19. Capa COS was ete tk tue eee cb ule tipi quo we V ro ae ue ese doe 98 Reformlhg tii ace ERE ERR DAN Wa n tun Lb UERBO C OC I dale ER 98 BEDS era ive eere Vet ide ud vu eb oett deed vovit sein 98 Technical data Whacthis chapter contains v Q1 uon o ese ce Ce Sete koc Bee LRL eS e e e de o ess 99 IEC TAUTES e Sh hin Peete oe rt fc Ohr NP edd lita irt ted Resa ar a De or Eu aac aL ae 99 SVIBIDOISt iss cio E E Gn OS be ARR UE ToO E Us et eMe e eee 100 SIZING deo eia a aee Pret e ER da cde e obeunt Bae oH dat Re Eat e cie qi 100 Derating sta DOR a p n pati e Mete ioo oe ep tas shal es de eade o6 imde b 100 Temperature derallnf rocas ke aa ee bos weeds een SDs ese Roe Sega ES 100 Al tude sderaubig suave ed m aret eo EYE EP HERPES Oke Da E we Ree EIS 100 Mains cable Tlses oo ex eR wei eae y ead Pode eases ey CREE Ra 101 Cabletypes ii dos S etd ee d edem a ier 102 Cable entries ud e ege e E E SHE RUE D adu ea ba px ur de wee EA ae RSS 102 Dimensions weights and noise o 102 Input POWErCONNECUON uu cs ex Rx eR ea eee A Cae Pa eae yy 103 MOTOR CONNECTOR ores cte ba oh oe reo x Ut UE ergs A E aha vd 103 ziulsi E M DEED 103 COON 2 iud uve um eR PA hu decebat Beute fes eene oe Reeth de Pater ted d Naro rote 104 Degrees of protection 0 eee rr rn 104 Ambient conditions boa YR EAM RE ye A RU EE CERE 104 uic c ITI EPI sl a o a A ls dl ea aa Y 105 Applicable Standards 45654 e ERR A AA bn 105 CE Marking 4 uns et ruso tee cde ibid e
20. Heatsink temperature check and cleaning Depends on the dustiness of the environment every 6 to 12 months See Heatsink Change of additional cooling fan Every three years See Additional fan Main cooling fan change Every six years See Main cooling fan Capacitor change Every ten years See Capacitors Maintenance 96 Heatsink The heatsink fins pick up dust from the cooling air The drive runs into overtemperature warnings and faults if the heatsink is not clean In a normal environment 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 Main cooling fan 2 Blow clean compressed air not humid from bottom to top and simultaneously use a vacuum Cleaner at the air outlet to trap the dust Note If there is a risk of the dust entering adjoining equipment perform the cleaning in another room 3 Replace the cooling fan Main cooling fan Maintenance 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
21. R6 238 8030 0100 5 234 132 100 114 75 R6 238 9570 0120 5 264 156 125 125 100 R6 238 11620 Three phase supply voltage 525 V 575 V or 600 V 0060 7 86 54 50 43 40 R6 238 5980 0070 7 120 75 60 60 50 R6 238 8030 0100 7 142 88 75 71 60 R6 238 9570 PDM code 00184674 H allowed with motor power lt 125 HP and a reactive power reference of O allowed with motor power lt 50 HP and a reactive power reference of 0 Symbols Technical data 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 Pn 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 long continuous rms current 50 96 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 Input cable fuses 111 The ratings of UL listed fuses for branch circuit protection are listed below The fuses also prevent damage to the adjoining equipment of the drive in case of a short circuit inside the drive Check that the operatin
22. Units without vibration dampers 1 Mark the locations for the four holes The mounting points are shown in chapter Dimensional drawings 2 Fix the screws or bolts to the marked locations 3 Position the drive onto the screws on the wall Note Lift the drive by its lifting holes not by its cover 4 Tighten the screws in the wall securely Units with vibration dampers In applications with considerable vibration in the frequency range of 50 Hz to 100 Hz vibration dampers can be used See ACS800 01 U1 Vibration Damper Installation Guide 3AFE68295351 English Appropriate vibration dampers are GC3 50MS kit code 68295581 for units of frame size R5 four dampers forunits of frame size R6 six dampers Note that the kit only includes four vibration dampers but units of frame size R6 require six Two dampers are installed in the middle Cabinet installation The drive can be installed in a cabinet without the plastic front top and connection box covers and without the lead through plate Vibration dampers are not needed The required distance between parallel units is 50 millimetres 1 97 in in installations without the front cover The cooling air entering the unit must not exceed 40 C 104 F Contact ABB if two units are to be installed side by side at a distance smaller than 50 millimetres 1 97 in i e the side air holes will be covered at one side When the external counter pressure increases the amount of
23. air flow through the heatsink of the drive is considerably reduced Therefore an additional fan is often needed in cabinet installation to boost the cooling An appropriate fan could be for example W2E200 HH38 06 230 V 50 60 HZ 67 79 W Y80 10012171 manufactured by EBM Papst which is capable of producing 550 m h when the counter pressure is 80 Pa Mechanical installation Preventing cooling air recirculation Prevent air recirculation inside and outside the cabinet Example Air baffle plates Ed COOL AREA Si Main air flow out 2 Main air flow in 35 Mechanical installation 36 Unit above another Lead the out coming hot cooling air away from the air input of the drive above Example max 40 C 104 F Mechanical installation 37 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 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 To
24. and commissioning flowchart llle 21 dare v i Fa sesh Ak Se vert o OREN e LRN Dic atk O EA O ELE Re IO a I 22 The ACS800 11 U11 What this chapter contains vede oes os ee ae OG ee te ee Phe E VE 23 The ACSSUU TI UII pie SN oes xot Oen o REOR XE NA 23 WORMS a AA e cse A A ccu Lx Lo CU EE ut E 25 Operation principle 25 v sob en dor Puede Piet Rath nnm aed hr ae Iota rend ee eid P ad 25 WEG SIE COMMON CB ss scs zer e Sora toe tiet e oC RE E d fat dcs nf vic et is eae Po dae Rs 25 AC voltage and current Wavefortmis 2 nene dnm ewe ew CREDE PRESE WERE E 26 MOTOR COMUOL Pra Irc cc DD 27 Printed Circuit DOSIUS ss seda mh id beeen boon ede pd f beak gate Re ae Ok ois 27 DDCS communication modules 6 0 5 3 seda put PRESS EMIL w od PEE oF Ain wa gigas 27 Main circuit and control diagram 22er a re RR Pee ee Ree EY Re A 28 TYPO code wknd a ate RE RC bed RUE AR EA a e ade A e MUR te ala Oh 29 Table of contents 14 Mechanical installation Unpacking ithe UNIte ses ote eR Rh A At E EE et eno RO ae 31 Delivery check iio soria ea m eR ERA ba ee RR ERO RE EUR GRO LARGO A e DR e eas o a 31 MOVING The HIDE octo ie BB te ena RC ebd REDE ER AAA A dues 32 Before Installation VS due EPI UE 33 Requirements for the installation Site 6 eee 33 rp IPIE TL IS 33 go pcc 33 Free space around the unit so eso ete tae Iu OR vis nice Boe oes Bato eee 33 Mounting the drive on the wall 0 0 0 00 n 34 Units without vibration
25. connections to the RMIO board for the ACS800 Standard Application Program Factory Macro are shown below For external control connections of other application macros and programs see the appropriate Firmware Manual 77 X2 RMIO X20 X20 RMIO 1 11 VREF Reference voltage 10 VDC 1 kohm R Terminal block size 2 12 AGND 10 kohm cables 0 3 to 3 3 mm 22 to 12 AWG X21 X21 Tightening torque r1 1 VREF Reference voltage 10 VDC 1 kohm lt R lt 0 2 to 0 4 Nm an 2 AGND 10 kohm 0 2 to 0 3 Ibf ft iS 13 Ali Speed reference 0 2 10 V Rin gt J l4 44 Al1 200 kohm 5 15 Al2 By default not in use O 4 20 mA Rin 6 16 AI2 100 ohm 7 7 Al3 By default not in use 0 4 20 mA Rin 8 18 Al3 100 ohm tpn 9 19 AO1 Motor speed O 4 20 mA 0 motor nom 10 10 AO1 speed R lt 700 ohm 11 11 AO2 Output current 0 4 20 mA O motor 7 12 112 AC2 nom current R lt 700 ohm optional terminal block in ACS800 02 x22 x22 AE ACERT e T TID Stop Start 1 Only effective if par 10 03 is set to 2 42 DI2 Forward Reverse REQUEST by the user 3 43 DI3 Not in use j 4 14 DIA Acceleration amp deceleration select 2 0 open 1 clo
26. daMperS ooooocoooc es 34 Units with vibration dampers 2 002 44 ose tebe CER UO EE ER RET DR Dee C CR d 34 GabihietimstallallDn s ruere acci m to eee ahs Si to acne EFE RD Tesis riu sive qe 34 Preventing cooling air recirculation tet eee 35 Unit above another vies A unt AA AA REO Ete Rcge RE Cp RUN e Re pr id 36 Planning the electrical installation What this chapter contains o oooooooo rrr 37 To which products this chapter applies 22 cruce RR ERE ERE e 37 Motor selection and compatibility ille 37 Protecting the motor insulation and bearings 00 cee ee 39 Requirements table purs pets esate Se Hele EE vad Ae eas BRI LEU se 40 Permanent magnet synchronous motor o 42 Supply Connectlon user Ai ERR DECR RO ERR et E T 43 Disconnecting device disconnecting means 0 ee ee 43 ACS800 01 ACS800 U1 ACS800 11 ACS800 U11 ACS800 31 ACS800 U31 ACS800 02 and ACS800 U2 without enclosure extension ACS800 04 ACS800 U4 43 ACS800 02 and ACS800 U2 with enclosure extension ACS800 07 and ACS800 U7 43 EU pec prp TII DECEM 43 MY gob aur 8 Ead atu Du det cent eds tede bue Seah to ee Gene a BE ee BE 43 FUSES Llc ps fo ew Linke We Meee aden ot Pea Rass Ona C REA eh how aa ace e ai aaa hs Rus 43 Thermal overload and short circuit protection 0 0 eens 44 Thermal overload protection 22 tice yest ERE e ex Eu Esc E 44 Short circuit protection 2 0 RR 9
27. default setting 7 24VD lt Es FOND P Grounds of input groups 11 DIIL 2 DI1 DI4 and DI5 DI6 DIIL 4 i or i are separate isolation DONIS uo voltage 50 V 1 24V 2 GND J lt X25 1 RO1 RO1 ap cem tu 3 RO1 X26 1 RO2 RO2 DE d 1 3 RO2 X27 1 RO3 2 RO3 e js 3 RO3 Test voltage Ground AS KI _____ oo NN NN Cll Motor control and I O board RMIO 82 Motor control and I O board RMIO 83 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 MECHANIC