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ABB ACS800-U7, Hardware Manual

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Table of contents

15

Replacing the additional fan at the lower part of the cubicle 
(R6 with du/dt filter, +E205)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Replacing the cabinet fans (frame size R8 only)  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Replacing the additional cabinet fan (frame sizes R7 and R8 only with IP22 and IP42 
when cabling: bottom entry/exit)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Replacing the additional cabinet fan (frame sizes R7 and R8 only with IP22 and IP42 
when cabling: top entry and bottom exit, bottom entry and top exit or top entry/exit)  . . . . . 101
Replacing the IP54 (UL type 12) fan in frame size R6 (B055 and +B059)  . . . . . . . 102
Replacing the IP54 (UL type 12) fan in frame sizes R7 and R8 (B055 and +B059)  103

Capacitors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Reforming   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Replacing the capacitor pack (R7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Replacing the capacitor pack (R8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Replacing the drive module (R5 and R6)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Replacing the drive module (R7 and R8)   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
LEDs  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Technical data

What this chapter contains   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
IEC data   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Symbols  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Sizing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Derating  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Temperature derating  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Altitude derating  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Fuses  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Calculation example  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Notes concerning the fuse tables  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Ultrarapid (aR) fuses   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Optional gG fuses  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Quick guide for selecting between gG and aR fuses  . . . . . . . . . . . . . . . . . . . . . . . . . 120

Cable types   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Cable entries  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Dimensions, weights and noise    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

NEMA data   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Symbols  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Sizing  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Derating  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Fuses  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

UL class T or L fuses   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Cable types   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Cable entries  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Dimensions, weights and noise      . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Free space around the unit    . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Input power connection  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Efficiency  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Summary of Contents for ACS800-U7

Page 1: ...ACS800 Hardware Manual ACS800 07 Drives 45 to 560 kW ACS800 U7 Drives 50 to 600 hp ...

Page 2: ...Standard Application Program 3AFE64590430 Pump Control Program Firmware Manual 3AFE68478952 Extruder Control Program Supplement 3AFE64648543 Centrifuge Control Program Supplement 3AFE64667246 Traverse Control Program Supplement 3AFE64618334 Crane Control Program Firmware Manual 3BSE11179 Adaptive Programming Application Guide 3AFE64527274 Option manuals and guides Safety options for ACS800 cabinet...

Page 3: ...ACS800 07 Drives 45 to 560 kW ACS800 U7 Drives 50 to 600 hp Hardware Manual 3AFE64702165 Rev H EN EFFECTIVE 2012 09 19 2012 ABB Oy All Rights Reserved ...

Page 4: ......

Page 5: ...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 General warning warns abou...

Page 6: ...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 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 e...

Page 7: ...quirements stated in EN 50178 WARNING Ignoring the following instructions can cause physical injury death or equipment malfunction and increase electromagnetic interference Ground the drive the 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 ...

Page 8: ...y damage electronic circuits in the cabinet When removing the module from the cabinet and manoeuvring it outside the cabinet prevent it from toppling over by securing it The drive module is heavy and has a high centre of gravity Beware of hot surfaces Some parts such as heatsinks of power semiconductors remain hot for a while after disconnection of the electrical supply WARNING Ignoring the follow...

Page 9: ...us situations can occur When activated these functions will reset the drive and resume operation after a fault 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 If an...

Page 10: ... 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 the drive input or output terminals L1 L2 L3 U2 V2 W2 UDC UDC Alternative 2 Measure that there is no voltage present on the drive input or output terminals L1 L2 L3 U2 V2 W2 UDC UDC Ground the dri...

Page 11: ...ble of contents Introduction to the manual What this chapter contains 17 Target audience 17 Categorization according to the frame size 17 Categorization according to the option code 17 Contents 18 Installation and commissioning flowchart 19 Terms and abbreviations 20 Operation principle and hardware description What this chapter contains 21 Product overview 21 Type designation key 23 Main circuit ...

Page 12: ... Additional requirements for non ABB high output and IP23 motors 43 Additional data for calculating the rise time and the peak line to line voltage 44 Additional note for sine filters 44 Additional note for common mode filters 44 Permanent magnet synchronous motor 45 Supply connection 45 Disconnecting device disconnecting means 45 EU 45 US 45 Fuses 45 Main contactor 45 Thermal overload and short c...

Page 13: ...of the assembly 61 Drive 61 Input cable 61 Motor and motor cable 61 Brake resistor assembly 62 Warning sticker 62 Example wiring diagram 63 Power cable connection diagram 64 Connecting the power cables 65 Additional instructions for frame size R6 66 Cable terminals R and R 66 Cable lug installations to R and R screws 66 Connecting the control cables 67 Routing the cables frame sizes R5 and R6 67 R...

Page 14: ...is chapter contains 85 Checklist 85 Start up procedure 86 Safety 86 Checks with no voltage connected 86 Starting the drive 86 Control program set up 86 On load checks 86 Maintenance What this chapter contains 87 Safety 87 Maintenance intervals 87 Required tools for maintenance 88 Cabinet layout 89 Frame sizes R5 and R6 89 Frame sizes R7 and R8 without du dt filter 90 Frame sizes R7 and R8 with du ...

Page 15: ...eforming 104 Replacing the capacitor pack R7 104 Replacing the capacitor pack R8 105 Replacing the drive module R5 and R6 106 Replacing the drive module R7 and R8 108 LEDs 111 Technical data What this chapter contains 113 IEC data 113 Ratings 113 Symbols 115 Sizing 115 Derating 115 Temperature derating 115 Altitude derating 115 Fuses 116 Calculation example 116 Notes concerning the fuse tables 117...

Page 16: ...ironment drive of category C3 135 Second environment drive of category C4 135 UL CSA markings 136 Equipment warranty and liability 136 Dimensional drawings Frame sizes R5 and R6 138 Frame sizes R7 and R8 139 IP54 and IP54R units of frame sizes R7 and R8 140 Resistor braking What this chapter contains 141 Availability of brake choppers and resistors 141 How to select the correct drive chopper resis...

Page 17: ...uctions for installations within the United States that must be performed per the National Electrical Code and local codes are marked with US Categorization according to the frame size Some instructions technical data and dimensional drawings which concern only certain frame sizes are marked with the symbol of the frame size R2 R3 or R8 The frame size is not marked on the drive designation label T...

Page 18: ... Electrical installation instructs how to wire the drive Motor control and I O board RMIO shows external control connections to the motor control and I O board and its specifications Installation checklist and start up helps in checking the mechanical and electrical installation of the drive Maintenance contains preventive maintenance instructions Technical data contains the technical specificatio...

Page 19: ...rs need to be reformed Ask ABB for instructions Check the installation site Mechanical installation Before installation Technical data If the drive is about to be connected to an IT ungrounded system check that the drive is not equipped with EMC filter E202 Operation principle and hardware description Type designation key For instructions on how to disconnect the EMC filtering contact ABB Route th...

Page 20: ...l EMC Electromagnetic compatibility EMI Electromagnetic interference IGBT Insulated gate bipolar transistor IT system Type of supply network that has no low impedance connection to ground earth NAIO Analogue I O extension module NDIO Digital I O extension module NRFC EMC filter board NTAC Pulse encoder interface module PE Protective earth PELV Protective extra low voltage POUS Prevention of unexpe...

Page 21: ...du dt filter E205 behind the swing out frame Denotes optional equipment not present on all units Line contactor Auxiliary circuit fuses IP21 22 UL type 1 Power and signal cable terminals and du dt filter E205 behind the swing out frame Note The input terminals are located in the EMC filter cubicle with E202 Swing out frame For layout of optional equipment on the swing out frame see Electrical inst...

Page 22: ...description 22 View of frame size R6 without shrouds IP21 22 View of frame size R5 without shrouds Power cable terminals Power cable terminals Drive module Drive module Additional fan not in all types RMIO RMIO See page 74 See page 74 ...

Page 23: ...mode filter in R8 one set of default language documents Size See Technical data IEC data or NEMA data Voltage range nominal rating in bold 3 380 400 415 VAC 5 380 400 415 440 460 480 500 VAC 7 525 575 600 690 VAC Optional selections Eg ACS800 07 0170 5 E202 Degree of protection B053 IP22 UL type 1 B054 IP42 UL type 2 B055 IP54 UL type 12 B059 IP54R with connection to air outlet duct Construction C...

Page 24: ... ACS800 Ordering Information EN code 64556568 Starter for auxiliary motor fan M600 1 1 6 A M601 1 6 2 5 A M602 2 5 4 A M603 4 6 3 A M604 6 3 10 A M605 10 16 A Control program Nxxx Refer to ACS800 Ordering Information EN code 64556568 Language of manual Rxxx Specialities P901 coated boards P902 customized P904 extended warranty P913 special colour P912 seaworthy packing P929 container packing Safet...

Page 25: ...l Door switches The following switches are mounted on the cabinet door Emergency stop button optional Operating switch units with main contactor only START position closes the main contactor ON position keeps the main contactor closed OFF position opens the main contactor ...

Page 26: ...storage which stabilizes the intermediate circuit DC voltage six pulse IGBT inverter converts the DC voltage to AC voltage and vice versa The motor operation is controlled by switching the IGBTs Motor control and I O board RMIO External control via analogue digital inputs and outputs Input power Output power R UDC UDC R Optional module 1 RMBA RAIO RDIO RDNA RLON RPBA RCAN RCNA RETA RRIA or RTAC Op...

Page 27: ...rotection board AIBP which includes varistors and snubbers for the thyristors power supply board APOW gate driver control board AGDR diagnostics and panel interface board ADPI EMC filter boards NRFC with option E202 brake chopper control board ABRC with option D150 Motor control The motor control is based on the Direct torque control DTC method Two phase currents and DC link voltage are measured a...

Page 28: ...Operation principle and hardware description 28 ...

Page 29: ...y truck and pallet truck to the installation site WARNING Lift the drive by the upper part only using the lifting lugs bars attached to the top of the unit Ma x 30 Cabinet back panel Support View of cabinet laid on its back It is allowed to tilt the drive if required or move it on its back when supported properly from below Note It is not allowed to move a unit with sine filter E206 on its back ...

Page 30: ...US and CSA markings a type designation key 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 year 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...

Page 31: ...lies on the two 100 mm wide transverse sections which the floor must carry Viewed from above Side view This area can be used for a cable channel With heavy cabinets support the structural C sections from below Prevent the cooling air flow from the cable channel to the cabinet by bottom plates To ensure the degree of protection for the cabinet use the original bottom plates delivered with the unit ...

Page 32: ...t The cabinet can be fastened against a wall or back to back with another cabinet See chapter Dimensional drawings for the horizontal and vertical fastening points Height adjustment can be done by using metal shims between the bottom frame and floor Fastening points when installed back against wall Fastening points when installed back against back Cabinet top M16 bolt L bracket Fastening the cabin...

Page 33: ...it with a bolt to the floor Fastening bolt M10 to M12 3 8 to 1 2 Cubicle width mm in Fastening hole distance in mm in 200 7 87 400 15 75 a 250 9 84 600 23 62 a 450 17 71 800 31 50 a 650 25 29 1000 39 37 a 350 13 78 b 150 5 91 a 350 13 78 1200 47 24 a 450 17 71 b 150 5 91 a 450 17 71 a b a 46 1 81 Dimensions of the fastening bracket Cabinet frame body Cabinet frame body ...

Page 34: ...is 800 mm 31 50 in a 1 0 5 IP54 IP20 42 Gap between the 200 mm 400 mm 600 mm 800 mm 1000 mm and 1500 mm cubicles 25 0 98 Side plates of the cabinet 15 mm Back plate of the cabinet 10 mm Fastening bolt M10 to M12 3 8 to 1 2 Cubicle width mm in Fastening hole distance in mm in 200 7 87 a 50 1 97 400 15 75 a 250 9 84 600 23 62 a 450 17 71 800 31 50 a 650 25 29 1000 39 37 a 350 13 78 b 150 5 91 a 350 ...

Page 35: ...he floor through the holes in each flat bar at the base of the cabinet using M10 or M12 screws 2 If there is not enough room behind the cabinet for installation clamp the rear ends of the flat bars 3 Remove the lifting lugs and bolt the fastening brackets into the lifting lug holes a Fasten the top of the cabinet to the rear wall and or roof with brackets b Fastening the cabinet at the top with br...

Page 36: ...ets with flat bars at the base marine versions If the fastening cannot be done using screws proceed as follows Weld only on the flat bar under the cabinet not the cabinet frame itself Clamp the welding electrode onto the flat bar about to be welded or onto the floor within 0 5 metres of the welding point WARNING If the welding return wire is connected improperly the welding circuit may damage elec...

Page 37: ...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 wi...

Page 38: ...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 equipped 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...

Page 39: ...d 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 i...

Page 40: ...15 frame size IEC 400 PN 134 hp and frame size NEMA 500 134 hp PN 469 hp or NEMA 500 frame size NEMA 580 ABB motors Random wound M2_ M3_ and M4_ UN 500 V Standard N 500 V UN 600 V Standard du dt du dt N or Reinforced N 600 V UN 690 V cable length 150 m Reinforced du dt du dt N 600 V UN 690 V cable length 150 m Reinforced N Form wound HX_ and AM_ 380 V UN 690 V Standard n a N CMF Old form wound HX_...

Page 41: ... the motor manufacturer if additional output filters are needed in the applied drive operation range Abbr Definition UN Nominal AC line voltage ÛLL Peak line to line voltage at motor terminals which the motor insulation must withstand PN Motor nominal power du dt du dt filter at the output of the drive option E205 CMF Common mode filter option E208 N N end bearing insulated motor non drive end bea...

Page 42: ...motor insulation requirements if the motor will be braking a large part of its operation time Example Motor insulation requirement for a 400 V AC line voltage application must be selected as if the drive were supplied with 480 V Additional requirements for ABB high output and IP23 motors The rated output power of high output motors is higher than what is stated for the particular frame size in EN ...

Page 43: ...me size IEC 400 PN 134 hp or frame size NEMA 500 134 hp PN 469 hp or NEMA 500 frame size NEMA 580 UN 420 V Standard ÛLL 1300 V N or CMF N CMF 420 V UN 500 V Standard ÛLL 1300 V du dt N or CMF du dt N CMF or Reinforced ÛLL 1600 V 0 2 microsecond rise time N or CMF N CMF 500 V UN 600 V Reinforced ÛLL 1600 V du dt N or CMF du dt N CMF or Reinforced ÛLL 1800 V N or CMF N CMF 600 V UN 690 V Reinforced ...

Page 44: ...n t 0 8 ÛLL du dt Additional note for sine filters Sine filters protect the motor insulation system Therefore du dt filter can be replaced with a sine filter The peak phase to phase voltage with the sine filter is approximately 1 5 UN Additional note for common mode filters Common mode filter is available as a plus code option E208 or as a separate kit one box including three rings for one cable A...

Page 45: ...drive the input cables and busbars must be isolated from the input power with a disconnector at the distribution board or at the supplying transformer 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 auxiliar...

Page 46: ... 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 thermal model or an actual temperature indication given by motor temperature sensors The user can tune the thermal model further by feed...

Page 47: ...e 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 3 Size ...

Page 48: ...sing the stop key on the control panel of the drive does not generate an emergency stop of the motor or separate the drive from dangerous potential An emergency stop function is optionally available for stopping and switching off the whole drive Two stop categories according to IEC EN 60204 1 1997 are available immediate removal of power Category 0 for ACS800 07 U7 and controlled emergency stop Ca...

Page 49: ... 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 d...

Page 50: ...ore 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 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 thi...

Page 51: ...Planning the electrical installation 51 ...

Page 52: ...r 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 shield...

Page 53: ...per tape or copper wire The better and tighter the shield the lower the emission level and bearing currents Symmetrical shielded cable three phase conductors and a concentric or otherwise symmetrically constructed PE conductor and a shield Recommended PE conductor and shield Shield Shield A separate PE conductor is required if the conductivity of the cable shield is 50 of the conductivity of the p...

Page 54: ...n 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 Cable Philsheath BICC General Corp Philsheath Rockbestos Co Gardex Oaknite CLX Shielded power cables are available from Belden LAPPKABEL ÖL...

Page 55: ...n 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 WARNING Never connect the supply power to the drive output termin...

Page 56: ...ds 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 protectiv...

Page 57: ... usable 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 for example Ö...

Page 58: ... drive For connection see the appropriate ACS800 Firmware Manual Installation sites above 2000 metres 6562 feet WARNING Protect against direct contact when installing operating and servicing 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 Routing the cables Rou...

Page 59: ...cable Input power cable Control cables min 200 mm 8 in min 300 mm 12 in Motor cable Power cable Drive 24 V 24 V 230 V Lead 24 V and 230 V 120 V control cables in separate ducts inside the cabinet Not allowed unless the 24 V cable is insulated for 230 V 120 V or insulated with an insulation sleeving for 230 V 120 V 120 V 230 V 120 V ...

Page 60: ...Planning the electrical installation 60 ...

Page 61: ... representative WARNING If a drive with EMC filter E202 is installed on an IT system an ungrounded power system or a high resistance grounded over 30 ohms power system the system will be connected to earth potential through the EMC filter capacitors of the drive This may cause danger or damage the unit Checking the insulation of the assembly Drive Do not make any voltage tolerance or insulation re...

Page 62: ...measurement Brake resistor assembly Check the insulation of the brake resistor assembly if present as follows 1 Check that the resistor cable is connected to the resistor and disconnected from the drive output terminals R and R 2 At the drive end connect the R and R conductors of the resistor cable together Measure the insulation resistance between the combined conductors and the PE conductor by u...

Page 63: ...ed which are not always included in the delivery Motor temperature supervision CDP312R control panel Switch fuse disconnector Main contactor Supply Temperature sensors for motor protection Alarm Signal control Drive module RDCU RMIO 3 Motor Cabinet Common mode filter du dt filter or 360 degrees grounding brake resistor Internal brake resistor External sine filter ...

Page 64: ...he phase conductor Ground the other end of the input cable shield or PE conductor at the distribution board 3 360 degrees grounding recommended if shielded cable 4 360 degrees grounding required 5 Use a separate grounding cable if the conductivity of the cable shield is 50 of the conductivity of the phase conductor and there is no symmetrically constructed grounding conductor in the cable see Plan...

Page 65: ...6 Connect the twisted shield of the cable to the PE terminal of the cabinet 7 Connect the phase conductors of the input cable to the L1 L2 and L3 terminals and the phase conductors of the motor cable to the U2 V2 and W2 terminals 8 Peel off 3 to 5 cm of the outer insulation of the cable above the lead through plate for the 360 high frequency earthing 9 Fasten the conductive sleeve to the cable shi...

Page 66: ...acturer Type Manufacturer Type No of crimps 6 Burndy YAV6C L2 Burndy MY29 3 1 Ilsco CCL 6 38 Ilsco ILC 10 2 4 Burndy YA4C L4BOX Burndy MY29 3 1 Ilsco CCL 4 38 Ilsco MT 25 1 2 Burndy YA2C L4BOX Burndy MY29 3 2 Ilsco CRC 2 Ilsco IDT 12 1 Ilsco CCL 2 38 Ilsco MT 25 1 1 Burndy YA1C L4BOX Burndy MY29 3 2 Ilsco CRA 1 38 Ilsco IDT 12 1 Ilsco CCL 1 38 Ilsco MT 25 1 Thomas Betts 54148 Thomas Betts TBM 8 3 ...

Page 67: ...mmets 1 and the EMI conductive cushions 2 to the swing out frame or the RMIO board as shown below Use sleeving wherever the cables are laid against sharp edges Leave some slack in the cable at the hinge 3 to allow the frame to open fully Tie the cables to the braces 4 to provide strain relief 1 2 3 4 4 3 4 Strain relief at the left side of the cabinet RMIO ...

Page 68: ...binet through the grommets 1 and the EMI conductive cushions 2 to the swing out frame as shown below Use sleeving wherever the cables are laid against sharp edges Leave some slack in the cable at the hinge 3 to allow the frame to open fully Tie the cables to the braces 4 to provide strain relief 1 2 3 4 4 4 ...

Page 69: ...two fastening screws 1 so that the EMI conductive cushions press tightly round the bare shield Note If the outer surface of the shield is non conductive Cut the shield at the midpoint of the bare part Be careful not to cut the conductors or the grounding wire if present Turn the shield inside out to expose its conductive surface Cover the turned shield and the stripped cable with copper foil to ke...

Page 70: ...net 3 Sort the cables in each group according to size 4 Group the cables for each grommet as follows ensuring that each cable has a proper contact to the cushions on both sides 5 Divide the bunches so that cables will be arranged according to size between the EMI conductive cushions 6 If more than one cable go through a grommet the grommet must be sealed by Loctite 5221 catalogue number 25551 Cabl...

Page 71: ...ing wires of the outer shield to the nearest grounding clamp Do not connect shields of different cables to the same grounding clamp Leave the other end of the shield unconnected or ground it indirectly via a few nanofarads high frequency capacitor for example 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 betw...

Page 72: ...sion module and the pulse encoder interface is inserted in the optional module slot of the RMIO board in the RDCU unit and fixed with two screws See the appropriate optional module manual for the cable connections Cabling of I O and fieldbus modules Set according to the supply voltage 380 V 400 V 415 V 440 V 480 V or 500 V or 525 V 575 V 600 V 660 V or 690 V Set to 220 V if the supply frequency is...

Page 73: ...ect them in a ring 2 3 4 1 Clamp as close to the terminals as possible As short as possible Note 1 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 Note 2 Twist the pair cable wires Note 3 The grounding wire of the out...

Page 74: ...pected start up option Q950 or Safe torque off option Q968 X10 earth fault protection 68328861 B Thermistor Pt100 relays Motor auxiliary fan circuit breaker Main contactor control relays Relay for Prevention of unexpected start up option Q950 or Safe torque off option Q968 Emergency stop of Category 1 Circuit breakers for cabinet heaters Earth fault protection device Denotes optional equipment not...

Page 75: ...e Thermistor Pt100 relays Relay for Prevention of unexpected start up option Q950 or Safe torque off option 968 Denotes optional equipment not present on all units AIMA board X2 X1 24 V external power supply Motor auxiliary fan devices RDCU RMIO Grounding clamps for RMIO Grounding clamps for X2 X5 X7 X8 X9 X4 X10 X6 Earth fault protection device Emergency stop of Category 1 Swing out frame front v...

Page 76: ...Electrical installation 76 ...

Page 77: ...also to optional terminal block X2 available for the 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 mm2 22 to 12 AWG Tightening torque for screw terminals is 0 4 to 0 8 Nm 0 3 to 0 6 lbf ft For disconnecting wires from spring terminals use a screw driver with a blade thickness of 0 6 mm 0 024 in and width of 3 5 mm ...

Page 78: ...secured mechanically to a location where it cannot come into contact with electrical parts If the screw terminal plug of the cable is removed the wire ends must be individually insulated WARNING If the RMIO board is powered from two power supplies connected to X23 and X34 and the external power supply connected to X23 is also used to power external equipment equip the RMIO branch of the circuit wi...

Page 79: ...nt speed select 3 7 7 24VD 24 V DC max 100 mA 8 8 24VD 9 9 DGND1 Digital ground 10 10 DGND2 Digital ground 11 11 DIIL Start interlock 0 stop 4 X23 X23 1 1 24V Auxiliary voltage output and input non isolated 24 V DC 250 mA 5 2 2 GND X25 X25 1 1 RO1 Relay output 1 ready 2 2 RO1 3 3 RO1 X26 X26 1 1 RO2 Relay output 2 running 2 2 RO2 3 3 RO2 X27 X27 1 1 RO3 Relay output 3 fault 1 2 2 RO3 3 3 RO3 Fault...

Page 80: ... speed select 3 7 7 24VD 24 V DC max 100 mA 8 8 24VD 9 9 DGND1 Digital ground 10 10 DGND2 Digital ground 11 11 DIIL Start interlock 0 stop 4 X23 X23 1 1 24V Auxiliary voltage output and input non isolated 24 V DC 250 mA 5 2 2 GND X25 X25 1 1 RO1 Relay output 1 ready 2 2 RO1 3 3 RO1 X26 X26 1 1 RO2 Relay output 2 running 2 2 RO2 3 3 RO2 X27 X27 1 1 RO3 Relay output 3 fault 1 2 2 RO3 3 3 RO3 Fault A...

Page 81: ...le potentiometer 1 kohm to 10 kohm Auxiliary power output Voltage 24 V DC 10 short circuit proof Maximum current 250 mA shared between this output and optional modules installed on the RMIO Analogue outputs Two programmable current outputs 0 4 to 20 mA RL 700 ohm Resolution 0 1 10 bit Inaccuracy 1 Full Scale Range at 25 C 77 F Temperature coefficient 200 ppm C 111 ppm F max Digital inputs With Sta...

Page 82: ...S ABB Distributed Drives Communication System 24 V DC power input Voltage 24 V DC 10 Typical current consumption without optional modules 250 mA 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 ex...

Page 83: ...ND1 5 DI5 6 DI6 7 24VD 8 24VD 11 DIIL 10 DGND2 X23 1 24 V 2 GND X25 1 RO1 2 RO1 3 RO1 X26 1 RO2 2 RO2 3 RO2 X27 1 RO3 2 RO3 3 RO3 Common mode voltage between channels 15 V J1 Test voltage 500 V AC or Jumper J1 settings All digital inputs share a common ground This is the default setting Grounds of input groups DI1 DI4 and DI5 DI6 DIIL are separate insulation voltage 50 V Ground Test voltage 4 kV A...

Page 84: ...Motor control and I O board RMIO 84 ...

Page 85: ...cal installation Motor selection and compatibility Technical data Motor connection The E202 EMC filter capacitors are disconnected if the drive is connected to an IT ungrounded system The capacitors are reformed if stored over one year refer to ACS 600 800 Capacitor Reforming Guide 64059629 English The drive is grounded properly The mains input power voltage matches the drive nominal input voltage...

Page 86: ...to set the drive parameters On load checks Check that the Prevention of unexpected start up function option Q950 if installed works For instructions see Safety options for ACS800 cabinet installed drives Q950 Q951 Q952 Q963 Q964 Q967 and Q968 Wiring start up and operation instructions 3AUA0000026238 English Optional function See delivery specific circuit diagrams Check that the cooling fans rotate...

Page 87: ...ilter check and change if necessary Cleanliness check Heatsink Every 6 years Cabinet cooling fan change frame sizes R5 and R6 Replacing the cabinet fans R5 and R6 Every 6 years Cabinet cooling fan change frame size R8 Replacing the cabinet fans frame size R8 only Every 6 years Change of additional cabinet cooling fan on the roof frame sizes R7 and R8 Replacing the additional cabinet fan frame size...

Page 88: ... R8 Replacing the IP54 UL type 12 fan in frame size R6 option B055 and B059 or Replacing the IP54 UL type 12 fan in frame sizes R7 and R8 option B055 and B059 Every 6 years Drive module cooling fan change frame sizes R5 and R6 Replacing the drive module fan R5 and R6 Every 6 years Drive module cooling fan change frame size R7 Replacing the drive module fan R7 Every 6 years Drive module cooling fan...

Page 89: ...9 Cabinet layout Cabinet layout stickers are shown below The symbols are described under Designations Frame sizes R5 and R6 The options included are marked with x at the factory IP54 ROOF OPTION 1 OPTION 2 OPTION 3 ...

Page 90: ...Maintenance 90 Frame sizes R7 and R8 without du dt filter The options included are marked with x at the factory IP22 42 BOTTOM ENTRY EXIT IP22 42 TOP ENTRY EXIT ...

Page 91: ...Maintenance 91 Frame sizes R7 and R8 with du dt filter The options included are marked with x at the factory IP22 42 BOTTOM ENTY EXIT IP22 42 BOTTOM ENTRY EXIT IP22 42 TOP ENTRY EXIT ...

Page 92: ... fan fuses F30 1 3 Motor auxiliary fan fuses F51 Circuit breaker G10 24 VDC external power supply K1 Line contactor Q1 F1 1 3 Switch fuse S11 Start Stop switch S20 Emergency Stop switch S21 Emergency Stop reset S90 Earth fault reset T10 Auxiliary voltage transformer T15 IP54 fan transformer U1 Drive module X2 Additional terminal block for RMIO board Y1 1 IP54 fan Y2 Additional cabinet fan Y3 1 IP2...

Page 93: ...the drive module are shown below The stickers show all possible components Not all of them are present in each delivery Components that need to be changed regularly are listed below Designation Component Y41 Cooling fan C_ Capacitors Code 64572261 Code 64601423 R7 R8 ...

Page 94: ... runs into overtemperature warnings and faults if the heatsink is not clean When necessary contact ABB for cleaning of the heatsink frame sizes R7 and R8 In frame size R6 proceed as follows 1 Remove the cooling fan see section Fans 2 Remove the drive module from the cabinet 3 Blow dry clean compressed air from bottom to top and simultaneously use a vacuum cleaner at the air outlet to trap the dust...

Page 95: ...Maintenance 95 Replacing the drive module fan R5 and R6 To remove the fan undo the fixing screws Disconnect the cable Install the fan in reverse order 1 2 Bottom view 1 ...

Page 96: ...t the fan supply wires detachable connector 5 Disconnect the fan capacitor wires 6 Disconnect the AINP board wires from connectors X1 and X2 7 Undo the red fixing screws of the fan cassette 8 Press the snap on holders to release the side cover 9 Lift the handle and pull the fan cassette out 10 Install the new fan and fan capacitor in reverse order to the above 3 3 3 4 7 7 8 8 9 DC DC 5 3 3 3 6 2 2...

Page 97: ...ply wires 3 Undo the red fastening screws of the plastic side cover of the fan Shift the cover to the right to free its right hand edge and lift the cover off 4 Undo the red fastening screws of the fan 5 Lift the fan out of the cabinet 6 Install the new fan and fan capacitor in reverse order to the above 5 4 4 2 2 3 3 ...

Page 98: ...ns in reverse order to the above Replacing the additional fan at the lower part of the cubicle R6 with du dt filter E205 1 Remove the screws that mount the support frame of the fan to the cabinet frame 2 Pull the fan support frame outwards and disconnect the fan supply wires detachable connector 3 Remove the fan frame from the cabinet 4 Remove the screws that mount the fan to the fan frame 5 Insta...

Page 99: ... on page 89 1 Undo the fastening screws 2 Disconnect the fan supply wires detachable connector at the back edge of the fan cassette 3 Pull the fan cassette out 4 Disconnect the fan wires from the terminal 5 Undo the fastening screws of the fans 6 Install the new fans in reverse order to the above 1 1 2 4 5 5 5 5 5 5 5 5 ...

Page 100: ...he fan cover by undoing the fastening screws 3 Disconnect the fan supply wires detachable connector and undo the cable ties on the fan cover 4 Remove the fan capacitor by undoing the fastening screw of the clamp 5 Pull the fan out 6 Install the new fan and fan capacitor in reverse order to the above 3 4 Pro E 6469 4952 cab r7 8_roof_fan_bot ee asm 6471 7154 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 ...

Page 101: ...om exit bottom entry and top exit or top entry exit 1 Remove the shroud by undoing the fastening screws 2 Disconnect the fan supply wires detachable connector 3 Remove the fan capacitor by undoing the fastening screw of the clamp 4 Install the new fan and fan capacitor in reverse order to the above 1 1 1 1 1 1 1 Pro E 6828 4759 2 ...

Page 102: ...fan cubicle by lifting it upwards 2 Remove the shroud by undoing the fastening screws 3 Disconnect the fan supply wires detachable terminal 4 Undo the fastening screws of the fan 5 Install the new fan in reverse order to the above Pro E 64784803A_ip54_roof 400 1 2 4 2 2 2 4 3 4 4 Cabinet front 64784803I_ip54_roof 400_b ee ...

Page 103: ...he fan supply wire connector from the cabinet roof on top and inside the cabinet 6 Undo the fastening screws of the fan cassette at each corner 7 Lift the fan cassette off 8 Undo the cable ties on the top of the fan cassette 9 Disconnect the cables detachable terminals 10 Remove the fan capacitor by undoing the fastening screw of the clamp 11 Undo the fastening screws of the fan 12 Pull the fan ou...

Page 104: ...tor failure is usually followed by damage to the unit and an input cable fuse failure or a fault trip Contact ABB if capacitor failure is suspected Replacements are available from ABB Do not use other than ABB specified spare parts Reforming Reform re age spare part capacitors once a year according to ACS 600 800 Capacitor Reforming Guide code 64059629 English Replacing the capacitor pack R7 Repla...

Page 105: ...8 on page 108 2 Remove the front cover Remove the profiled side plate 3 Disconnect the discharging resistor wires 4 Undo the red fastening screws 5 Lift the capacitor pack out 6 Install the new capacitor pack in reverse order to the above 4 4 3 3 M10 M6 2 pcs M6x12 combi screw 4 4 4 4 4 5 At the rear side view from below 2 pcs in 690 V units 3 ...

Page 106: ...he shroud at the top of the module by undoing the fastening screws 7 Remove the shrouds in the lower part of the cabinet 8 Remove the additional fan if any See Replacing the additional fan at the lower part of the cubicle R6 with du dt filter E205 on page 98 9 Disconnect the control cables by detaching the RMIO board terminals 10 Disconnect the power busbars and cables Note Drives with safety func...

Page 107: ...abinet to the sides of the cabinet 12 Undo the fastening screws of the module Use a torque wrench with an extension bar 13 R5 Lift the module out R6 Slide the module out onto a pallet truck 14 Install the new module in reverse order to the above 13 12 12 12 12 11 11 ...

Page 108: ... Disconnect the door wires 6 Remove the air guide 7 Remove the fastening bracket 8 Remove the front cover of the module 9 Disconnect the fibre optic cables from the AINT board and mark down the terminals for reconnecting Note Drives with safety functions options Q963 Q964 Q965 Q966 or Q968 Disconnect the STO cable from the module 8 1 6 3 5 9 7 View when the module cover is removed 4 Photos of fram...

Page 109: ...ing b screws b b b Frame size R8 M10x25 combi screws Tightening torque 30 44 Nm 22 32 lbf ft b b b b b b a a M6x16 combi screws Tightening torque 5 Nm 3 7 lbf ft a M6 combi screw Tightening torque 5 Nm 3 7 lbf ft M8x25 combi screw Tightening torque 15 22 Nm 11 16 lbf ft a b Frame size R7 b b a a a a a a b ...

Page 110: ...stening of screws a is important because the screws are required for the grounding of the drive 11 12 WARNING Secure the module properly The module of frame size R7 weighs 90 kg 198 lb The module of frame size R8 weighs 200 kg 441 lb The centre of gravity of the module is high The module is slid in on the pedestal rails view from back the back plate of the cabinet removed ...

Page 111: ...Control panel mounting platform Red Drive in fault state Green The main 24 V power supply for the control panel and the RMIO board is OK AINT board V204 green 5 V voltage of the board is OK V309 red Prevention of unexpected start up option Q950 or Safe torque off option Q968 is ON V310 green IGBT control signal transmission to the gate driver control boards is enabled ...

Page 112: ...Maintenance 112 ...

Page 113: ...vy duty use Frame size Air flow Heat dissipation Icont max A Imax A Pcont max kW I2N A PN kW I2hd A Phd kW m3 h W Three phase supply voltage 380 V 400 V or 415 V 0075 3 145 170 75 141 75 100 45 R5 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 3...

Page 114: ...1 200 285 200 234 160 R6 405 4500 0320 5 440 588 250 435 250 340 200 R8 1220 6850 0400 5 515 588 315 510 315 370 250 R8 1220 7800 0440 5 550 840 355 545 355 490 315 R8 1220 7600 0490 5 602 840 400 590 400 515 2 355 R8 1220 8100 0550 5 684 1017 450 670 450 590 2 400 R8 1220 9100 0610 5 718 1017 500 704 500 632 3 450 R8 1220 9700 Three phase supply voltage 525 V 550 V 575 V 600 V 660 V or 690 V 0070...

Page 115: ...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 10 C 90 or 0 90 The output current is then 0 90 I2N 0 90 I2hd or 0 90 Icont max Altitude derating At altitudes from 1000 to 4000 m 3281 to 13123 ft above sea level the derating is 1 for every ...

Page 116: ...rt circuit current of the installation is at least the value given in the fuse table The short circuit current can be calculated as follows where Ik2 ph short circuit current in symmetrical two phase short circuit U network line to line voltage V Rc cable resistance ohm Zk zk UN 2 SN transformer impedance ohm zk transformer impedance UN transformer rated voltage V SN nominal apparent power of the ...

Page 117: ...protection on page 46 For UL recognized fuses see section NEMA data on page 123 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 mentione...

Page 118: ...ann 170M3819 DIN1 0165 5 222 2210 500 145 000 690 Bussmann 170M5810 DIN2 0205 5 256 2620 550 190 000 690 Bussmann 170M5811 DIN2 0255 5 286 2620 550 190 000 690 Bussmann 170M5811 DIN2 0320 5 424 4000 800 465 000 690 Bussmann 170M6812 DIN3 0400 5 498 5550 1000 945 000 690 Bussmann 170M6814 DIN3 0440 5 543 7800 1250 1 950 000 690 Bussmann 170M8554 DIN3 0490 5 590 7800 1250 1 950 000 690 Bussmann 170M...

Page 119: ...0 1 0165 5 222 3820 250 550 000 500 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 0320 5 424 8280 500 2 900 000 500 ABB Control OFAF3H500 3 0400 5 498 10200 630 4 000 000 500 ABB Control OFAF3H630 3 0440 5 543 10200 630 4 000 000 500 ABB Control OFAF3H630 3 0490 5 590 10200 630 4 000 000 500 ABB Control OFAF3...

Page 120: ...0 730 0490 3 3 3 150 Cu 3 3 240 Al 700 770 930 490 530 730 Three phase supply voltage 380 V 400 V 415 V 440 V 460 V 480 V or 500 V 0105 5 3 70 Cu 3 95 Al 160 170 190 130 130 150 0120 5 3 95 Cu 3 120 Al 190 200 220 140 140 150 0140 5 3 95 Cu 3 150 Al 190 200 220 160 160 160 0150 5 3 120 Cu 3 185 Al 220 230 250 180 180 180 0165 5 3x150 Cu 3x240 Al 250 260 290 200 200 200 0205 5 3 185 Cu 3 240 Al 290...

Page 121: ...n 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 three ladder type trays one on top of the other ambient temperature 30 C 86 F PVC insulation surface temperature 70 C 158 F EN 60204 1 and IEC 60364 5 52 2001 For other conditions size the cables acc...

Page 122: ...D151 SAFURxxxFxxx 400 mm 2xSAFURxxxFxxx 800 mm 4xSAFURxxxFxxx 1600 mm 3 extra width for units with EMC filter E202 200 mm 4 extra width for units with EMC filter E202 400 mm 5 in marine applications C121 depth with fastening bars 700 mm Frame size L1 L2 L3 U2 V2 W2 UDC R UDC R Earthing PE Number of holes per phase Hole diameter Max wire size Screw Tightening torque Screw Tightening torque mm mm2 N...

Page 123: ... 440 V 460 V 480 V 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 0165 5 326 220 150 165 125 R6 238 11140 0205 5 326 245 200 215 150 R6 238 12980 0270 5 480 316 250 240 200 R8 718 15350 0300 5 568 361 300 302 250 R8 718 18050 0320 5 588 435 350 340 250 R8 718 23250 0400 5 588 510 400 370 300 R8 718 26650 0440 5 840 545 450 490 400...

Page 124: ...n 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 Note 5 Circuit breakers must not be used without fuses Imax max...

Page 125: ...ann JJS 600 T 0440 5 501 800 600 Ferraz A4BY800 L 0490 5 542 800 600 Ferraz A4BY800 L 0550 5 614 800 600 Ferraz A4BY800 L 0610 5 661 800 600 Ferraz A4BY800 L Three phase supply voltage 525 V 575 V or 600 V 0070 7 70 100 600 Bussmann JJS 100 T 0100 7 82 125 600 Bussmann JJS 125 T 0120 7 103 150 600 Bussmann JJS 150 T 0145 7 121 200 600 Bussmann JJS 200 T 0175 7 150 200 600 Bussmann JJS 200 T 0205 7...

Page 126: ...pper cables with concentric copper shield Max load current A Cable type AWG kcmil 57 6 75 4 88 3 101 2 114 1 132 1 0 154 2 0 176 3 0 202 4 0 224 250 MCM or 2 1 251 300 MCM or 2 1 0 273 350 MCM or 2 2 0 295 400 MCM or 2 2 0 334 500 MCM or 2 3 0 370 600 MCM or 2 4 0 or 3 1 0 405 700 MCM or 2 4 0 or 3 2 0 449 2 250 MCM or 3 2 0 502 2 300 MCM or 3 3 0 546 2 350 MCM or 3 4 0 590 2 400 MCM or 3 4 0 669 ...

Page 127: ...RxxxFxxx 62 99 in 3 extra width for units with EMC filter E202 7 87 in 4 extra width for units with EMC filter E202 15 75 in 5 in marine applications C121 depth with fastening bars 27 56 in Frame size L1 L2 L3 U2 V2 W2 UDC R UDC R Earthing PE Max cable Screw Tightening torque Screw Tightening torque kcmil AWG lbf ft lbf ft R6 350 MCM 3 8 14 8 29 5 3 8 22 32 R7 2 250 MCM 1 2 37 55 3 8 22 32 R8 3 70...

Page 128: ...ired free space around the unit for cooling Front Side Above mm in mm in mm in R5 150 5 91 400 15 75 R6 150 5 91 400 15 75 R7 150 5 91 400 15 75 R8 150 5 91 400 15 75 IP54 IP21 22 42 400 mm 15 75 in 400 mm 15 75 in 320 mm 12 28 in for fan replacement in frame sizes R7 and R8 Frame sizes R5 and R6 400 mm 15 75 in Frame sizes R7 and R8 800 mm 31 5 in ...

Page 129: ...age U2 0 to L1 3 phase symmetrical Umax at the field weakening point Frequency DTC mode 0 to 3 2 fFWP Maximum frequency 300 Hz fFWP fFWP frequency at field weakening point UNmains mains input power voltage UNmotor nominal motor voltage fNmotor nominal motor frequency Frequency resolution 0 01 Hz Current See section IEC data Power limit 1 5 Phd 1 1 PN or Pcont max whichever value is greatest Nomina...

Page 130: ...dity 5 to 95 Max 95 Max 95 No condensation allowed Maximum allowed relative humidity is 60 in the presence of corrosive gases Contamination levels IEC 60721 3 3 IEC 60721 3 2 IEC 60721 3 1 No conductive dust allowed Boards without coating Chemical gases Class 3C1 Solid particles Class 3S2 Boards with coating Chemical gases Class 3C2 Solid particles Class 3S2 Boards without coating Chemical gases C...

Page 131: ...in 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 The drive complies with the standards below The compliance with the European Low Voltage Directive is verified according to standards EN 61800 5 1 and EN 60204 1 IEC EN 6180...

Page 132: ...ioning 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 w...

Page 133: ...y transformer with static screening between the primary and secondary windings can be used 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 dr...

Page 134: ...e 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...

Page 135: ... the standard can be met as follows 1 It is ensured that no excessive emission is propagated to neighbouring low voltage networks In some cases the natural suppression in transformers and cables is sufficient If in doubt the supply transformer with static screening between the primary and secondary windings is strongly recommended 2 An EMC plan for preventing disturbances is drawn up for the insta...

Page 136: ...multiple drives with DC bus connected to allow a sharing of regenerative energy 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 pe...

Page 137: ...ensional drawings with dimensions in millimetres and inches are shown below See ACS800 07 U7 Dimensional Drawings 3AFE 64775421 English for location of cable connection terminals units with EMC filter du dt filter and brake resistors marine units US drawings ...

Page 138: ...Dimensional drawings 138 Frame sizes R5 and R6 64778340_1 5 K ...

Page 139: ...Dimensional drawings 139 Frame sizes R7 and R8 68749930_1 7 C ...

Page 140: ...Dimensional drawings 140 IP54 and IP54R units of frame sizes R7 and R8 68749930_6 6 C ...

Page 141: ...The following condition must be met where 3 Check the resistor selection The energy generated by the motor during a 400 second period must not exceed the resistor heat dissipation capacity ER If the ER value is not sufficient it is possible to use a four resistor assembly in which two standard resistors are connected in parallel two in series The ER value of the four resistor assembly is four time...

Page 142: ... R6 113 SAFUR125F500 4 3600 9 0135 3 R6 132 SAFUR200F500 2 70 5400 13 5 0165 3 R6 132 SAFUR200F500 2 70 5400 13 5 0205 3 R6 160 SAFUR200F500 2 70 5400 13 5 0260 3 R8 240 240 240 173 2XSAFUR210F575 1 70 8400 21 0320 3 R8 300 300 300 143 2xSAFUR200F500 1 35 10800 27 0400 3 R8 375 375 273 130 4xSAFUR125F500 1 00 14400 36 0440 3 R8 473 355 237 120 4xSAFUR210F575 0 85 16800 42 0490 3 R8 500 355 237 120...

Page 143: ...e Pbrcon t The 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 ER R Resistance value for the resistor assembly Note This is also the minimum allowed resistance for the brake resistor ER Short energy pulse ...

Page 144: ...ter Pbr5 or Pbr10 braking the drive and the chopper will withstand Pbr30 within a total braking time of 30 seconds Pbr10 braking is not acceptable after Pbr5 braking Combined braking cycles for R8 After Pbr5 Pbr10 or Pbr30 braking the drive and the chopper will withstand Pbrcont continuously Pbrcont is the only allowed braking power after Pbr5 Pbr10 or Pbr30 Pbr5 Pbr10 or Pbr30 braking is allowed ...

Page 145: ...le 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 If ordered the resistors are factory installed in a cubicle s next to the drive cabinet Protection of frame size R5 It is highly recommended to equip the drive with a main contactor for safety reasons Wire the contactor so that...

Page 146: ...fferent 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 Check the resistance value setting parameter 27 03 Frame sizes R6 R7 and R8 Check the setting of...

Page 147: ...uct training For information on ABB product training navigate to www abb com drives and select Training courses Providing feedback on ABB Drives manuals Your comments on our manuals are welcome Go to www abb com drives and select Document Library Manuals feedback form LV AC drives Document library on the Internet You can find manuals and other product documents in PDF format on the Internet Go to ...

Page 148: ...3AFE64702165 Rev H EN 2012 09 19 Contact us www abb com drives www abb com drivespartners ...

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