ABB ACS800-37-0060-3 Hardware Manual
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ABB ACS800-37-0060-3 Hardware Manual

Acs800-37 series drives (55 to 2700 kw / 75 to 3000 hp)
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ACS800
Hardware Manual
ACS800-37 Drives (55 to 2700 kW / 75 to 3000 HP)

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Summary of Contents for ABB ACS800-37-0060-3

  • Page 1 ACS800 Hardware Manual ACS800-37 Drives (55 to 2700 kW / 75 to 3000 HP)
  • Page 3 ACS800-37 Drives 55 to 2700 kW (75 to 3000 HP) Hardware Manual 3AFE68557925 REV B EN EFFECTIVE: 01.11.2005 © 2005 ABB Oy. All Rights Reserved.

  • Page 5: Safety Instructions

    Safety instructions What this chapter contains This chapter contains safety instructions you must follow when installing, operating and servicing the drive. If ignored, physical injury or death may follow, or damage may occur to the drive, the motor or driven equipment. Read the safety instructions before you work on the unit.

  • Page 6: Installation And Maintenance Work

    Installation and maintenance work These warnings are intended for all who work on the drive, motor cable or motor. Ignoring the instructions can cause physical injury or death, or damage the equipment. WARNING! • Only qualified electricians are allowed to install and maintain the drive. •...
  • Page 7 WARNING! • During the installation procedure, supply, filter or inverter modules may have to be temporarily extracted from the cabinet. The modules have a high centre of gravity. In order to minimise the danger of toppling over, keep the support legs (if provided) of the modules extended whenever manoeuvring the modules outside the cabinet.

  • Page 8: Grounding

    Grounding These instructions are intended for all who are responsible for the grounding of the drive. Incorrect grounding can cause physical injury, death or equipment malfunction and increase electromagnetic interference. WARNING! • Ground the drive, the motor and adjoining equipment to ensure personnel safety in all circumstances, and to reduce electromagnetic emission and pick- •...

  • Page 9: Operation

    Operation These warnings are intended for all who plan the operation of the drive or operate the drive. Ignoring the instructions can cause physical injury or death or damage the equipment. WARNING! • Before adjusting the drive and putting it into service, make sure that the motor and all driven equipment are suitable for operation throughout the speed range provided by the drive.

  • Page 10: Permanent Magnet Motor Drives

    Permanent magnet motor drives These are additional warnings concerning permanent magnet motor drives. WARNING! Do not work on the drive when the permanent magnet motor is rotating. Also when the supply power is switched off, a rotating permanent magnet motor feeds power to the intermediate circuit of the drive and also the supply connections become live (even when the inverter is stopped!).

  • Page 11: Table Of Contents

    Table of contents Safety instructions What this chapter contains ............5 Usage of warnings and notes .
  • Page 12 Door switches .............36 Main switch-disconnector (Q1 in frame size R6 to R8i) .
  • Page 13 Permanent magnet synchronous motor ..........64 Thermal overload and short-circuit protection .
  • Page 14 Connection procedure ............81 Motor connection –...
  • Page 15 Installation checklist ............101 Start-up procedure .
  • Page 16 Technical data What this chapter contains ............123 IEC ratings .
  • Page 17 Frame size 6×R8i ............. 207 Resistor braking What this chapter contains .

  • Page 18: Table Of Contents

    Table of contents...

  • Page 19: About This Manual

    About this manual What this chapter contains This chapter describes the intended audience and contents of the manual. It contains a flowchart of steps in checking the delivery, installing and commissioning the drive. The flowchart refers to chapters/sections in this manual and other manuals.

  • Page 20: Installation And Commissioning Flowchart

    If the drive is For instructions on how to disconnect the EMC/ about to be connected to an IT (ungrounded) system, RFI filtering, contact your local ABB check that the drive is not equipped with EMC/RFI representative.

  • Page 21: Inquiries

    Address any inquiries about the product to the local ABB representative, quoting the type code and serial number of the unit. If the local ABB representative cannot be contacted, address inquiries to ABB Oy, AC Drives, PO Box 184, 00381 Helsinki, Finland.

  • Page 22: Terms And Abbreviations

    Type of optical branching unit used for connecting parallel-connected converter modules to the RDCU. Common mode filtering. DDCS Distributed Drives Communication System; a protocol used in optical fibre communication inside and between ABB drives. Drive unit See Motor-side converter. Electromagnetic Compatibility. Frame (size) Relates to the construction type of the component in question.

  • Page 23: The Acs800-37

    The ACS800-37 What this chapter contains This chapter describes the construction of the drive in short. The ACS800-37 The ACS800-37 is a cabinet-built, low-harmonic drive for controlling AC motors. Cabinet line-up The drive consists of one or more cubicles that contain the supply and motor terminals, 1 to 6 IGBT supply module(s) forming the line-side converter, 1 to 6 inverter modules forming the motor-side converter, and optional equipment.

  • Page 24: Frame R6

    Frame R6 The picture below shows the main components of a frame R6 drive with the door open, and with the swing-out frame closed (left) and open (right). Description Swing-out frame (see page 27) Cable entries for power and control cables (bottom cable entry/exit models) Cable entries for power and control cables (top cable entry/exit models)

  • Page 25: Frame R7I

    Frame R7i The picture below shows the main components of a frame R7i drive with the door and the swing-out frame open. Description Swing-out frame (see page 27) (not shown). The drive control units for both converter modules are installed on the swing-out frame.

  • Page 26: Frame R8I

    Frame R8i The picture below shows the main components of a frame R8i drive with the doors open. Description Swing-out frame (see picture on page 27) Supply unit controller (RDCU) Inverter unit controller (RDCU) Switch-disconnector* Input contactor* LCL filter IGBT supply module Intermediate DC link Inverter module Cooling fan for LCL filter...

  • Page 27: Swing-Out Frame

    Swing-out frame The swing-out frame provides space for the control circuitry of the drive as well as optional electrical equipment. The frame can be opened by removing the two locking screws (arrowed in the picture below) and moving the swing-out frame aside. Depending on the frame size of the drive, the actual equipment of the drive may differ from what is depicted.
  • Page 28 The following is a generic device layout diagram for the swing-out frame (drive frame size R8i). The diagram is also attached to the inside of the cubicle door, with installed devices marked. Refer to the circuit diagrams delivered with the drive for device designations.

  • Page 29: Cabling Direction

    Cabling direction The drawing below shows the available power cabling directions of the drive. Frame size R6 Description Input/Motor output – Bottom entry IP21-42 IP54 Input/Motor output – Top entry (IP21-42) Input/Motor output – Top entry (IP54) Signal cable input/output – Bottom entry Signal cable input/output –...
  • Page 30 Frame size R8i Description Input/output cubicle Supply and inverter unit cubicle Common motor terminal cubicle (optional)* Standard input (bottom entry) Standard input (top entry) Standard output (bottom exit) Standard output (top exit) Optional output (bottom exit, 1st Environment) Optional output (top exit, 1st Environment); additional depth 130 mm Motor output –...

  • Page 31: Single-Line Circuit Diagram Of The Drive

    Single-line circuit diagram of the drive Note: This diagram represents a frame 2×R8i drive without a common motor terminal cubicle. The ACS800-37...

  • Page 32: Operation Principle

    Operation principle The line-side and motor-side converters have their own RDCU control units and control programs. The parameters of each program can be viewed and changed using one control panel. The converter to be controlled can be selected using the control panel;...

  • Page 33: Ac Voltage And Current Waveforms

    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 voltage depends slightly on the Short Circuit Ratio in the Point of Common Coupling (PCC).

  • Page 34: Motor-Side Converter

    Motor-side converter The motor control is based on the Direct Torque Control (DTC) method. Two phase currents and DC link voltage are measured and used for the control. The third phase control is measured for earth fault (ground fault) protection. The motor-side converter is controlled by an RDCU drive control unit located in the swing-out frame of the cabinet.

  • Page 35: Controls

    Controls Control interfaces of the drive The following diagram shows the control interfaces and I/O options of the drive. The ACS800-37...

  • Page 36: Door Switches

    Door switches Main switch-disconnector (Q1 in frame size R6 to R8i) The switch-disconnector handle switches the main and auxiliary voltages to the drive on and off. Air circuit breaker (Q1 in frame size 2×R8i and up) The air circuit breaker controls the main supply voltage (phases L1, L2 and L3). For more information on using the breaker, refer to its manual.

  • Page 37: Control Panel

    Control panel A control panel (type CDP-312R) is installed on the door of the drive. The CDP-312R is the user interface of the supply unit (line-side converter) and the inverter unit (motor-side converter) of the drive, providing the essential controls such as Start/ Stop/Direction/Reset/Reference, and the parameter settings for the units’...

  • Page 38: Fieldbus Control Of The Line-Side Converter

    Fieldbus control of the line-side converter Fieldbus control of the line-side converter is performed via the motor-side converter RMIO board as shown in the block diagram below. Block diagram: reference select The figure below shows the parameters for DC and reactive power reference selection.

  • Page 39: Type Code

    + signs (e.g. +E202). The main selections are described below. Note: The information below is for quick reference only and does not contain all conditions and details. For more information, refer to ACS800 Ordering Information (code: 64556568), available through ABB representatives. Frame sizes R6, R7i and R8i Selection...

  • Page 40: Frame Sizes 2×R8I To 6×R8I

    Selection Alternatives Cabling H351 = Top entry H353 = Top exit H358 = US/UK gland/conduit plate H359 = Common motor terminal cubicle – Frame R8i with +E202 only Auxiliary voltage G304 = 115 V AC – Standard with +C129 and +C134 Cabinet options G300 = Cabinet heaters (external supply) –...
  • Page 41 Selection Alternatives Construction C121 = Marine construction (reinforced mechanical parts and fastening, marking of conductors [A1], door handles, self-extinctive materials) C129 = UL Listed – Includes +H358 C134 = CSA Approved – Includes +H358 Resistor braking D150 = Brake chopper(s). D151 = Brake resistors.
  • Page 42 The ACS800-37...

  • Page 43: Mechanical Installation

    Mechanical installation What this chapter contains This chapter describes the mechanical installation procedure of the drive. General See chapter Technical data for allowable operating conditions and requirements for free space around the unit. The unit should be installed in an upright vertical position. The floor that the unit is installed on should be of non-flammable material, as smooth as possible, and strong enough to support the weight of the unit.

  • Page 44: Moving The Unit

    Moving the unit …by crane Use the steel lifting lugs attached to the top of the cabinet. Insert the lifting ropes or slings into the holes of the lifting lugs. The lifting lugs can be removed (not mandatory) once the cabinet is in its final position. If the lifting lugs are removed, the bolts must be refastened to retain the degree of protection of the cabinet.

  • Page 45: By Fork-Lift Or Pallet Truck

    …by fork-lift or pallet truck The centre of gravity may be quite high. Be therefore careful when transporting the unit. Tilting the cabinets must be avoided. The units are to be moved only in the upright position. If using a pallet truck, check its load capacity before attempting to move the unit.

  • Page 46: Final Placement Of The Unit

    Final placement of the unit The cabinet can be moved into its final position with an iron bar and a wooden piece at the bottom edge of the cabinet. Care is to be taken to properly place the wooden piece so as not to damage the cabinet frame. Mechanical installation...

  • Page 47: Before Installation

    Before installation Delivery check The drive delivery contains: • drive cabinet line-up • optional modules (if ordered) installed into the control rack at the factory • ramp for extracting supply and inverter modules from the cabinet • hardware manual • appropriate firmware manuals and guides •...

  • Page 48: Installation Procedure

    Installation procedure See detailed instructions in the following few pages. (1) The cabinet can be installed with its back against a wall, or back-to-back with another unit. Fasten the unit (or first shipping split) to the floor with fastening clamps or through the holes inside the cabinet.

  • Page 49: Fastening The Cabinet To The Floor (Non-Marine Units)

    Fastening the cabinet to the floor (Non-marine units) The cabinet is to be fastened to the floor by using clamps along the edge of the cabinet bottom, or by bolting the cabinet to the floor through the holes inside. Clamping Insert the clamps into the twin slots along the front and rear edges of the cabinet frame body and fasten them to the floor with a bolt.

  • Page 50: Holes Inside The Cabinet

    Holes inside the cabinet The cabinet can be fastened to the floor using the fastening holes inside the cabinet, if they are accessible. The recommended maximum distance between the fastening points is 800 mm (31.5”). If there is not enough working space behind the cabinet for mounting, replace the lifting lugs at the top with L-brackets (not included) and fasten the top of the cabinet to the wall.

  • Page 51: Fastening The Unit To The Floor And Wall (Marine Units)

    Fastening the unit to the floor and wall (Marine units) The unit must be fastened to the floor and roof (wall) as follows: Bolt the unit to the floor through the holes in each flat bar at the base of the cabinet using M10 or M12 screws.

  • Page 52: Joining The Shipping Splits

    Joining the shipping splits The busbar systems and wiring harnesses of two shipping splits are joined in the common motor terminal cubicle (if present) or a busbar joining cubicle. Special M6 screws for fastening the shipping splits together are enclosed in a plastic bag inside the rightmost cubicle of the first shipping split.

  • Page 53: Connecting The Dc Busbars And The Pe Busbar

    • Remove any intermediate or partitioning plates covering the rear posts of the joining cubicle. Partitioning plate Intermediate plate Busbar joining Back posts accessible cubicle • Fasten the rear post of the joining section with seven screws (below the busbar joining part) to the rear post of the next cubicle.

  • Page 54: Dc Busbars

    DC busbars The DC busbar connection is shown below. Joint pieces Tighten the bolts to 55–70 Nm (40–50 ft.-lbs.) Side view of single busbar connection PE busbar The PE busbar runs continuously through the line-up near the floor at the back. The connection is shown below.

  • Page 55: Miscellaneous

    Miscellaneous Cable conduit in the floor below the cabinet A cable conduit can be constructed below the 400 mm wide middle part of the cabinet. The cabinet weight lies on the two 100 mm wide transverse sections which the floor must carry. Side view Viewed from above With heavy...

  • Page 56: Cooling Air Intake Through Bottom Of Cabinet

    Cooling air intake through bottom of cabinet Units with air intake through the bottom of the cabinet (optional feature) are intended for installation on an air duct in the floor. The required air inlets in the floor are as listed below. Refer also to the dimensional drawings delivered with the unit. •...

  • Page 57: Electric Welding

    Electric welding It is not recommended to fasten the cabinet by welding. Cabinets without flat bars at the base • Connect the return conductor of the welding equipment to the cabinet frame at the bottom within 0.5 metres of the welding point. Cabinets with flat bars at the base •...
  • Page 58 Mechanical installation...

  • Page 59: Planning The Electrical Installation

    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.

  • Page 60: Protecting The Motor Insulation And Bearings

    3. Check that the motor voltage rating meets the application requirements: If the drive is equipped with … … and … … then the motor voltage rating should be … diode supply no resistor braking is used (ACS800-01, ACS800-U1, frequent or long-term brake cycles ACeq1 ACS800-02, ACS800-U2, are used...

  • Page 61: Requirements Table

    The stress on motor insulation can be avoided by using optional ABB du/dt filters. du/dt filters also reduce bearing currents. To avoid damage to motor bearings, the cables must be selected and installed according to the instructions given in this manual. In addition, insulated N-end (non- driven end) bearings and output filters from ABB must be used according to the following table.
  • Page 62 Note 3: High-output motors and IP 23 motors For motors with higher rated output than what is stated for the particular frame size in EN 50347 (2001) and for IP 23 motors, the requirements of ABB random-wound motor series M3AA, M3AP, M3BP are Planning the electrical installation...
  • Page 63 All AMA machines (manufactured in Helsinki) for drive systems have form-wound windings. All HXR machines manufactured in Helsinki starting 1.1.1998 have form-wound windings. Note 5: ABB motors of types other than M2_, M3_, HX_ and AM_ Use the selection criteria given for non-ABB motors.

  • Page 64: Permanent Magnet Synchronous Motor

    Û du/dt ------------ - (1/µs) Û du/dt ------------ - (1/µs) Cable length (m) Cable length (m) With du/dt Filter Without du/dt Filter Note 9: Sine filters Sine filters protect the motor insulation system. Therefore, a du/dt filter can be replaced with a sine filter.

  • Page 65: Supply (Ac Line) Cable Short-Circuit Protection

    Supply (AC line) cable short-circuit protection Always protect the input cable with fuses. In networks with a short-circuit withstand of 65 kA or less, standard gG fuses can be used. No fuses need be installed at the drive input. If the drive is supplied through busbars, fuses must be installed at the drive input. In networks with a short-circuit withstand of less than 50 kA, standard gG fuses are sufficient.

  • Page 66: Prevention Of Unexpected Start

    Prevention of unexpected start The drive can be equipped with an optional prevention of unexpected start function according to standards IEC/EN 60204-1: 1997; ISO/DIS 14118: 1996 and EN 1037: 1996. The circuit conforms to EN954-1, Category 3. The function is achieved by disconnecting the control voltage to the power semiconductors of the inverters of the drive.

  • Page 67: Selecting The Power Cables

    Selecting the power cables General rules Dimension the supply (input power) and motor cables according to local regulations: • The cable must be able to carry the drive load current. See chapter Technical data for the rated currents. ° • The cable must be rated for at least 70 C maximum permissible temperature of conductor in continuous use.

  • Page 68: Alternative Power Cable Types

    Alternative power cable types Power cable types that can be used with the drive are represented below. Recommended Symmetrical shielded cable: three phase conductors A separate PE conductor is required if the conductivity and a concentric or otherwise symmetrically of the cable shield is < 50 % of the conductivity of the constructed PE conductor, and a shield phase conductor.

  • Page 69: Additional Us Requirements

    Additional US requirements Type MC continuous corrugated aluminum armor cable with symmetrical grounds or shielded power cable must be used for the motor cables if metallic conduit is not used. For the North American market, 600 VAC cable is accepted for up to 500 VAC. 1000 VAC cable is required above 500 VAC (below 600 VAC).

  • Page 70: Power Factor Compensation Capacitors

    Power factor compensation capacitors Power factor compensation is not needed with AC drives. However, if a drive is to be connected in a system with compensation capacitors installed, note the following restrictions. WARNING! Do not connect power factor compensation capacitors to the motor cables (between the drive and the motor).

  • Page 71: Before Opening An Output Contactor (In Dtc Motor Control Mode)

    Before opening an output contactor (in DTC motor control mode) Stop the drive and wait for the motor to stop before opening a contactor between the output of the drive and the motor when the DTC control mode is selected. (See the Firmware Manual of the drive for the required parameter settings.) Otherwise, the contactor will be damaged.

  • Page 72: Selecting The Control Cables

    Control panel cable In remote use, the cable connecting the control panel to the drive must not exceed 3 metres (10 ft). The cable type tested and approved by ABB is used in control panel option kits. Coaxial cable (for use with Advant Controllers AC 80/AC 800) •...

  • Page 73: Connection Of A Motor Temperature Sensor To The Drive I/O

    Connection of a motor temperature sensor to the drive I/O WARNING! IEC 60664 requires double or reinforced insulation between live parts and the surface of accessible parts of electrical equipment which are either non- conductive or conductive but not connected to the protective earth. To fulfil this requirement, the connection of a thermistor (and other similar components) to the digital inputs of the drive can be implemented in three alternate ways:...

  • Page 74: Control Cable Ducts

    A diagram of the cable routing is below. Motor cable Drive min 300 mm (12 in.) Power cable Input power cable Motor cable 90 ° min 200 mm (8 in.) min 500 mm (20 in.) Control cables Control cable ducts 24 V 230/120 V 24 V...

  • Page 75: Electrical Installation

    Electrical installation What this chapter contains This chapter describes the electrical installation procedure of the drive. WARNING! Only qualified electricians are allowed to carry out the work described in this chapter. Follow the Safety instructions on the first pages of this manual. Ignoring the safety instructions can cause injury or death.

  • Page 76: Before Installation

    EMC filter +E202, disconnect the filter before connecting the drive to the supply network. For detailed instructions on how to do this, please contact your local ABB representative. WARNING! If a drive with EMC filter +E202 is installed on an IT system [an...

  • Page 77: Input Power Connection - Frame R6

    Input power connection – Frame R6 Connection diagram Connection procedure Note: Before making the cable connections, check that the input of the auxiliary voltage transformer (T10) is selected correctly according to the supply voltage. 1. Open the door of the cabinet. 2.

  • Page 78: Input Power Connection - Frame R7I

    Input power connection – Frame R7i Connection diagram Connection procedure Note: Before making the cable connections, check that the input of the auxiliary voltage transformer (T10) is selected correctly according to the supply voltage. 1. Open the door of the cabinet. 2.

  • Page 79: Input Power Connection - Frame Size R8I

    Input power connection – Frame size R8i Connection diagram Connection procedure Note: Before making the cable connections, check that the tap settings of the auxiliary voltage transformer (T10, located in the input/output cubicle) are correct in regard to the supply voltage. See instructions on page 94. 1.

  • Page 80: Input Power Connection - Frame Size 2×R8I And Up

    Input power connection – Frame size 2×R8i and up Connection diagram U< Connection procedure 1. Open the door of the incoming cubicle (see section Cabling direction starting on page 29). 2. Remove any shrouds that protect the input busbars and cable entries. 3.

  • Page 81: Motor Connection - Frame R6

    Motor connection – Frame R6 Connection diagram Connection procedure 1. Open the cabinet door. 2. Remove any shrouds that protect the output busbars and cable entries. 3. Lead the cables into the inside of the cubicle. It is recommended to apply 360° grounding of the cable shields at the entry as shown below.

  • Page 82: Motor Connection - Frame R7I

    Motor connection – Frame R7i Connection diagram Connection procedure 1. Open the cabinet door. 2. Remove any shrouds that protect the output busbars and cable entries. 3. Lead the cables into the inside of the cubicle. It is recommended to apply 360° grounding of the cable shields at the entry as shown below.

  • Page 83: Motor Connection - Frame R8I Units Without Option +E202 Or +H359

    Motor connection – Frame R8i units without option +E202 or +H359 Connection diagram Supply and inverter unit cubicle Input/output cubicle Connection procedure Note: Before making the cable connections, consider checking the tap settings of the auxiliary voltage transformer located in the input/output cubicle. See instructions on page 94.

  • Page 84: Motor Connection - Frame R8I With Option +E202 But Without +H359

    Motor connection – Frame R8i with option +E202 but without +H359 Output busbars The motor cables are to be connected to the output busbars behind the inverter module. For the location and dimensions of the busbars, see the chapter Dimensions. Connection diagram Inverter unit cubicle Connection procedure...
  • Page 85 Electrical installation...
  • Page 86 Lead the cables into the cabinet at the inverter module. Make the 360° earthing arrangement at the cable entry as shown. Cut the cables to suitable length. Strip the cables and conductors. Twist the cable screens into bundles and connect to cabinet PE (ground) busbar. Connect any separate ground conductors/cables to cabinet PE (ground) busbar.

  • Page 87: Motor Connection - Units With Common Motor Terminal Cubicle (+H359)

    Motor connection – Units with common motor terminal cubicle (+H359) Connection diagram Inverter unit cubicle(s) Common motor terminal cubicle Connection procedure 1. Open the door of the common motor terminal cubicle (see section Cabling direction starting on page 29). 2. Remove any shrouds that protect the output busbars and cable entries. 3.

  • Page 88: Motor Connection - Frame 2×R8I And Up Without Common Motor Terminal Cubicle

    Motor connection – Frame 2×R8i and up without common motor terminal cubicle Output busbars The motor cables are to be connected to the output busbars behind each inverter module. For the location and dimensions of the busbars, see the chapter Dimensions.

  • Page 89: Connection Procedure

    Connection procedure WARNING! The inverter modules are heavy and have a high centre of gravity. Be careful when manoeuvring the modules. In order to minimise the danger of toppling over, keep the support legs of the modules extended whenever manoeuvring the modules outside the cabinet. Extract each inverter module from the cubicle as follows (refer to the pictures below): 1.
  • Page 90 Lead the cables into the cabinet at the inverter module. Make the 360° earthing arrangement at the cable entry as shown. Cut the cables to suitable length. Strip the cables and conductors. Twist the cable screens into bundles and connect to cabinet PE (ground) busbar. Connect any separate ground conductors/cables to cabinet PE (ground) busbar.

  • Page 91: Control Connections

    Control connections Drive control connections The control connections are made on the terminal blocks provided in the swing-out frame of the drive. Refer to the circuit diagrams delivered with the drive, and to the chapter Motor control and I/O board (RMIO).
  • Page 92 Units with EMI conductive cushions only: Run the cables between the cushions as shown below. Strip the cable at this location to enable proper connection of the bare shield and the cushions. Tighten the cushions firmly onto the cable shields. Side view Strain relief EMI conductive...

  • Page 93: Installation Of Optional Modules And Pc

    Installation of optional modules and PC Optional modules (such as fieldbus adapters, I/O extension modules and pulse encoder interfaces) are inserted into the optional module slot of the RMIO boards (built in the RDCU drive control units) and secured with two screws.

  • Page 94: Tap Settings Of The Auxiliary Voltage Transformer (Frame R8I And Up)

    Tap settings of the auxiliary voltage transformer (Frame R8i and up) 3~ Input Output 3~ input 1~ output 3~ output Tap settings 230 V 115 V 400 V (50 Hz) 320 V (60 Hz) Supply Supply Terminals voltage voltage A1 to... B1 to… C1 to… Terminals Terminals Terminals...

  • Page 95: Motor Control And I/O Board (Rmio)

    Motor control and I/O board (RMIO) What this chapter contains This chapter shows • external control connections to the RMIO board for the the ACS 800 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 the RMIO-01 board (revision J or later) or the RMIO-02 board (revision H or later).

  • Page 96: External Control Connections (Non-Us)

    External control connections (non-US) External control cable connections to the RMIO board for the ACS 800 Standard Application Program (Factory Macro) are shown below. For external control connections of other application macros and programs, see the appropriate Firmware Manual. Terminal block size: VREF- Reference voltage -10 VDC, 1 kohm <...

  • Page 97: External Control Connections (Us)

    External control connections (US) External control cable connections to the RMIO board for the ACS 800 Standard Application Program (Factory Macro US version) are shown below. For external control connections of other application macros and programs, see the appropriate Firmware Manual. Terminal block size: VREF- Reference voltage -10 VDC, 1 kohm <...

  • Page 98: Rmio Board Specifications

    RMIO board specifications Analogue inputs With Standard Application Program two programmable differential current inputs (0 mA / 4 mA ... 20 mA, R = 100 ohm) and one programmable differential voltage input (-10 V / 0 V / 2 V ... +10 V, R >...

  • Page 99: Relay Outputs

    Maximum continuous current 2 A rms Isolation test voltage 4 kVAC, 1 minute DDCS fibre optic link With optional communication adapter module RDCO. Protocol: DDCS (ABB Distributed Drives Communication System) 24 VDC power input Voltage 24 VDC ± 10% Typical current consumption...
  • Page 100 Isolation and grounding diagram (Test voltage: 500 V AC) VREF- AGND VREF+ AGND AI1+ Common mode AI1- voltage between AI2+ channels ±15 V AI2- AI3+ AI3- AO1+ AO1- AO2+ AO2- Jumper J1 settings: DGND1 All digital inputs share a common ground.

  • Page 101: Installation Checklist And Start-Up

    Installation checklist and start-up What this chapter contains This chapter contains an installation checklist, a start-up procedure for the drive, and listings of parameters specific to the ACS800-37. Installation checklist Check the mechanical and electrical installation of the drive before start-up. Go through the checklist below together with another person.

  • Page 102: Start-Up Procedure

    Check… For drives with Category 1 Emergency stop function: The time relay has been set to a suitable value (e.g. somewhat longer than the stop ramp of the inverter units). All shrouds are in place. Start-up procedure Action Additional information WARNING! Ensure that the disconnector of the supply transformer is locked to open position, i.e.

  • Page 103: Starting The Supply Unit

    Note: The output voltage of the drive can be raised using a parameter setting; for example, it is possible to run a 500 V motor off a 400 V supply. Contact your local ABB representative for more information. Application program set-up...

  • Page 104: Acs800-37-Specific Parameters In The Igbt Supply Control Program

    ACS800-37-specific parameters in the IGBT Supply Control Program The signals and parameters described in the tables below are included in the IGBT Supply Control Program. Terms and abbreviations Term Definition Boolean Character string Def. Default value FbEq Fieldbus equivalent: the scaling between the value shown on the control panel and the integer used in serial communication Integer Real...

  • Page 105: Fixed Parameters With The Acs800-37

    Name/Value Description T./FbEq Def. 31.02 TRIAL TIME Defines the time for the automatic fault reset function. See parameter 30 s 31.01. 1.0 … 180.0 s Allowed resetting time 100 … 18000 31.03 DELAY TIME Defines the time that the drive will wait after a fault before attempting an automatic reset.

  • Page 106: Acs800-37-Specific Parameters In The Application Program

    ACS800-37-specific parameters in the application program The actual signals and parameters described in this section are included in the ACS800 Standard Application Program. Terms and abbreviations Term Definition Actual signal Signal measured or calculated by the drive. Can be monitored by the user.

  • Page 107: Actual Signals And Parameters Of Line-Side Converter In Motor-Side Converter Program

    Actual signals and parameters of line-side converter in motor-side converter program Name/Value Description FbEq Def. 09 ACTUAL SIGNALS Signals from the line converter. 09.12 LCU ACT SIGNAL 1 Line converter signal selected by par. 95.08 LCU PAR1 SEL. 1 = 1 09.13 LCU ACT SIGNAL 2 Line converter signal selected by par.
  • Page 108 Installation checklist and start-up...

  • Page 109: Maintenance

    • ensure there is no dangerous voltage present by measuring the voltage of the input terminals and the intermediate circuit terminals. Maintenance intervals If installed in an appropriate environment, the drive requires very little maintenance. This table lists the routine maintenance intervals recommended by ABB. Interval Maintenance action Instruction...

  • Page 110: Reduced Run Capability

    Reduced run capability If one of the parallel-connected supply or inverter modules must be taken out of the cabinet for service, it is possible to continue operation at reduced power using the remaining modules. Note: This function is only available if the drive is equipped with a PPCS branching unit of type APBU-xx.

  • Page 111: Quick Connectors (Frame R8I And Up)

    Quick connectors (Frame R8i and up) 1. Read and repeat the steps in section Safety instructions above. 2. Open the cabinet doors. 3. Extract one supply or inverter module from the cabinet as described in the connection procedures in the chapter Electrical installation.

  • Page 112: Cooling Fans

    Cooling fans Supply/Inverter module cooling fan replacement (Frame R6) 1. Read and repeat the steps in section Safety instructions above. 2. Loosen the fastening screws of the top plate. 3. Lift the top plate upwards and pull it out. 4. Disconnect the fan supply wires (detachable connector). 5.

  • Page 113: Supply/Inverter Module Cooling Fan Replacement (Frame R7I)

    Supply/Inverter module cooling fan replacement (Frame R7i) 1. Disconnect the wire plug. 2. Remove the two screws holding the fan unit. 3. Pull the fan unit slightly towards the front of the cubicle, then downwards to free it. 4. Install new fan in reverse order. Maintenance...

  • Page 114: Lcl Filter Module Cooling Fan Replacement (Frame R7I)

    LCL filter module cooling fan replacement (Frame R7i) 1. Disconnect the wire plug (1). 2. Remove the two screws holding the fan unit (2). 3. Pull the fan unit out (3). 4. Install new fan in reverse order. Maintenance...

  • Page 115: Supply And Inverter Module Cooling Fan Replacement (Frame R8I And Up)

    The actual lifespan depends on the running time of the fan, ambient temperature and dust concentration. Each supply and inverter module has its own cooling fan. Replacements are available from ABB. Do not use other than ABB specified spare parts.

  • Page 116: Lcl Filter Cooling Fan Replacement (Frame R8I And Up)

    The lifespan of the cooling fans of the LCL filter modules is about 60 000 hours. The actual lifespan depends on the running time of the fan, ambient temperature and dust concentration. Replacements are available from ABB. Do not use other than ABB specified spare parts.

  • Page 117: Cabinet Fan Replacement (Frame R6)

    Cabinet fan replacement (Frame R6) 1. Read and repeat the steps in section Safety instructions above. 2. Open the cubicle door. 3. Remove the shroud covering the top of the cubicle. 4. Disconnect the fan wiring. Make note of the connections at the terminal block. 5.

  • Page 118: Cabinet Fan Replacement (Frame R8I And Up With Ip54)

    Cabinet fan replacement (Frame R8i and up with IP54) 1. Remove the front and back gratings of the fan cubicle by lifting them upwards. 2. Remove the shrouds by undoing the fastening screws. 3. Undo the fastening screws of the side/top cover of the fan. 4.

  • Page 119: Heatsinks

    Capacitor life can be prolonged by lowering the ambient temperature. It is not possible to predict capacitor failure. Capacitor 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.

  • Page 120: Other Maintenance Actions

    Other maintenance actions Power module replacement (Frame R8i and up) To replace power modules (i.e. supply and inverter modules), follow the instructions on module removal and refitting given in the chapter Electrical installation. Maintenance...

  • Page 121: Fault Tracing

    Fault Tracing Faults and warnings displayed by the CDP-312R Control Panel The control panel will display the warnings and faults of the unit (i.e. supply unit or inverter unit) the panel is currently controlling. The warnings and faults concerning the inverter unit (motor-side converter) are dealt with in the application program (e.g.

  • Page 122: Leds Of The Drive

    LEDs of the drive Location Indication RMIO board (RDCU drive control Fault state. unit) Green The power supply on the board is OK. Control panel mounting platform Fault state. (with the control panel removed) Green The main + 24 V power supply for the control panel and the RMIO board is OK.

  • Page 123: What This Chapter Contains

    Heavy-duty Heat dissi- Noise ratings load use overload use pation flow level ACS800-37 type cont.max cont.max Three-phase supply voltage 380 V, 400 V or 415 V ACS800-37-0060-3 ACS800-37-0070-3 ACS800-37-0100-3 ACS800-37-0140-3 1300 ACS800-37-0170-3 1300 ACS800-37-0210-3 3160 ACS800-37-0260-3 3160 ACS800-37-0320-3 3160 ACS800-37-0390-3...

  • Page 124: Symbols

    Nominal No-over- Light- Heavy-duty Heat dissi- Noise ratings load use overload use pation flow level ACS800-37 type cont.max cont.max ACS800-37-1820-5 2037 2956 1400 1956 1300 1524 1000 10240 ACS800-37-2200-5 2529 3670 1800 2428 1700 1892 1350 12800 Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V, or 690 V ACS800-37-0170-7 1300 ACS800-37-0210-7...

  • Page 125: Derating

    At altitudes from 1000 to 4000 m (3281 to 13123 ft) above sea level, the derating is 1% for every 100 m (328 ft). For a more accurate derating, use the DriveSize PC tool. If the installation site is higher than 2000 m (6600 ft) above sea level, please contact your local ABB distributor or office for further information.

  • Page 126: Nema Ratings

    NEMA ratings The ratings for the ACS800-37 with a 60 Hz supply are given below. The symbols are described below the table. Heavy-duty Heat dis- Noise Nominal ratings Normal use Air flow sipation level ACS800-37 type cont.max Btu/h /min Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V or 480 V ACS800-37-0070-5 8200 ACS800-37-0100-5...

  • Page 127: Symbols

    Symbols Nominal ratings Maximum output current. Allowable for 10 seconds at start, otherwise as long as allowed by drive temperature. Typical motor power. The power ratings apply to most 4-pole NEMA-rated motors at cont.max nominal voltage (460 or 575 V). Normal use (10% overloadability) Continuous rms current.

  • Page 128: Acs800-37 Frame Sizes And Power Module Types

    ACS800-37 frame sizes and power module types Supply module(s) used LCL filter(s) used Inverter modules used ACS800-37 type Frame size Type Type Type Three-phase supply voltage 380 V, 400 V or 415 V ACS800-37-0060-3 ACS800-11-0060-3* ACS800-37-0070-3 ACS800-11-0070-3* ACS800-37-0100-3 ACS800-11-0100-3* ACS800-37-0140-3 ACS800-104-0145-3 ALCL-04-5 ACS800-104-0145-3...

  • Page 129: Ac Fuses

    • The recommended fuses are for branch circuit protection per NEC as required for UL approval. AC fuse information Drive type aR, IEC aR, UL Recognized Bussmann Ferraz Shawmut Bussmann Ferraz Shawmut 400 V ACS800-37-0060-3 170M3814 – 170M3014 – ACS800-37-0070-3 170M3815 – 170M3015 – ACS800-37-0100-3 170M3816 –...

  • Page 130: Dc Fuses

    • Fuses from other manufacturers can be used if they meet the ratings. • The recommended fuses are for branch circuit protection per NEC as required for UL approval. DC fuse information Drive type UL Recognized Bussmann Ferraz Shawmut Bussmann 400 V ACS800-37-0060-3 … – – – – – – ACS800-37-0510-3 ACS800-37-0640-3 170M8552 6.9URD3PV1000...

  • Page 131: Input Power Connection

    Input power connection Voltage (U 380/400/415 VAC 3-phase ± 10% for 400 VAC units 380/400/415/440/460/480/500 VAC 3-phase ± 10% for 500 VAC units 525/550/575/600/660/690 VAC 3-phase ± 10% for 690 VAC units Prospective short-circuit 65 kA (I ) for units without grounding switch. current (IEC 60439-1, 50 kA (I ) for units with grounding switch.
  • Page 132 Input terminals L1/L2/L3 – Bottom cable entry/exit Frame R6 Front view Bolt size: M10 Tightening torque: 40 Nm (29.5 lbf.ft) Top cable entry/exit Front view Bolt size: M10 Tightening torque: 40 Nm (29.5 lbf.ft) Input terminals L1/L2/L3 – Side view Frame R7i Bolt size: M12 or ½”...

  • Page 133: Motor Connection

    Input terminals L1/L2/L3 – Front view Frame R8i Bolt size: M12 or ½” Tightening torque: 70 Nm (52 lbf.ft) Input terminals L1/L2/L3 – Front view Frame 2×R8i and up Bolt size: M12 or ½” Tightening torque: 70 Nm (52 lbf.ft) Motor connection Voltage (U 0 to U...
  • Page 134 Output terminals U2/V2/W2 Bottom cable entry/exit – Frame R6 Front view Bolt size: M10 Tightening torque: 40 Nm (29.5 lbf.ft) Top cable entry/exit Front view Bolt size: M10 Tightening torque: 40 Nm (29.5 lbf.ft) Output terminals U2/V2/W2 Front view – Frame R7i Bolt size: M12 or ½”...
  • Page 135 Standard output terminals Bottom or top exit U2/V2/W2 – Frame R8i Front view Bolt size: M12 or ½” Frame R8i units without option Tightening torque: 70 Nm (52 lbf.ft) +E202 (EMC/RFI filtering for 1st Environment) or +H359 (common motor terminal cubicle) Output terminals at each R8i Bottom exit...

  • Page 136: Efficiency

    Maximum recommended 100 m (328 ft). Motor cables up to 500 m (1640 ft) long are allowed but EMC filtering motor cable length within the specified limits will not be realised. Efficiency > 97% (at rated current and nominal supply voltage) Cooling Method Internal fans, flow direction from bottom to top...

  • Page 137: Materials

    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. Tightening torques for power connections Screw size Torque M5 3.5 Nm (2.6 lbf.ft)
  • Page 138 • EN 61800-3 (2004) Adjustable speed electrical power drive systems. Part 3: EMC requirements and specific test methods • UL 508C UL Standard for Safety, Power Conversion Equipment, second edition • CSA C22.2 No. 14-95 Industrial control equipment Technical data...

  • Page 139: Ce Marking

    CE marking A CE mark is attached to the drive to verify that the unit follows the provisions of the European Low Voltage and EMC Directives (Directive 73/23/EEC, as amended by 93/68/EEC and Directive 89/336/ EEC, as amended by 93/68/EEC). Definitions EMC stands for Electromagnetic Compatibility.

  • Page 140: Second Environment (Drive Of Category C3)

    Equipment 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.

  • Page 141: C-Tick" Marking

    “C-tick” marking “C-tick” marking is required in Australia and New Zealand. A “C-tick” mark is attached to each drive in order to verify compliance with the relevant standard (IEC 61800-3 (2004) – Adjustable speed electrical power drive systems. Part 3: EMC product standard including specific test methods), mandated by the Trans-Tasman Electromagnetic Compatibility Scheme.

  • Page 142: Second Environment (Drive Of Category C3)

    Equipment 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.

  • Page 143: Equipment Warranty And Liability

    NOT LIMITED TO, ANY IMPLIED WARRANTIES OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. If you have any questions concerning your ABB drive, please contact the local distributor or ABB office. The technical data, information and specifications are valid at the time of printing. The manufacturer reserves the right to modifications without prior notice.
  • Page 144 Technical data...

  • Page 145: What This Chapter Contains

    Dimensions What this chapter contains This chapter contains a table of weights as well as dimensional drawings of the different frame sizes of the ACS800-37. Weights The following table shows the approximate weights of all ACS800-37 types (without options). Weight ACS800-37-…...

  • Page 146: Frame R6

    Frame R6 Dimensions...
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  • Page 150: Frame R7I

    Frame R7i Dimensions...
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  • Page 157: Frame R8I (Without Option +E202)

    Frame R8i (without option +E202) Dimensions...
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  • Page 165: Frame Size R8I (With Option +E202)

    Frame size R8i (with option +E202) Dimensions...
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  • Page 170: Frame Size 2×R8I

    Frame size 2×R8i Dimensions...
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  • Page 183: Frame Size 3×R8I

    Frame size 3×R8i Dimensions...
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  • Page 189: Frame Size 4×R8I

    Frame size 4×R8i Dimensions...
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  • Page 195: Frame Size 5×R8I

    Frame size 5×R8i Dimensions...
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  • Page 207: Frame Size 6×R8I

    Frame size 6×R8i Dimensions...
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  • Page 219: What This Chapter Contains

    Resistor braking options The following ACS800-37 drives are available with brake choppers and resistors. For information on braking equipment for other ACS800-37 types, or custom resistor braking equipment, contact your local ABB representative. ACS800-37 type Brake chopper type (+D150) Brake resistor type (+D151) ACS800-37-0060-3 •...

  • Page 220: Chopper/Resistor Combinations - Technical Data

    Chopper/Resistor combinations – Technical data The following table contains the technical data of selected chopper/resistor combinations. Duty cycle Duty cycle (10/60 s) (1/5 min) Airflow brmax cont Chopper(s) Resistors (ohm) (kW) (kW) (kW) (kW) 1 × NBRA-658 2 × SAFUR210F575 2500 1 ×...

  • Page 221: Brake Choppers - Technical Data

    = DC voltage at which chopper stops conducting br_off Airflow = Airflow required for cooling of chopper Brake resistors – Technical data The following table contains the technical data for the resistors supplied by ABB. Airflow Rcont Type (ohm)

  • Page 222: Verifying The Capacity Of The Braking Equipment

    Verifying the capacity of the braking equipment 1. Calculate the maximum power (P ) generated by the motor during braking. 2. Ensure the following condition is met: > P brmax The P values specified in the technical data table above are for the reference braking cycle brmax (1 minute of braking, 9 minutes of rest).

  • Page 223: Calculating The Maximum Braking Power (P Br )

    Calculating the maximum braking power (P • Braking energy transferred during any ten minute period must be less than or equal to the energy transferred during the reference braking cycle. • The braking power must not exceed the rated maximum value P brmax n ×...

  • Page 224: Example 3

    Example 3 Duration of a braking cycle is three minutes. The braking time is 10 seconds. × 60 s brmax < = 1.5 · P brmax 4 × 10 s brmax 600 s T = Duration of the braking cycle >...

  • Page 225: Custom Resistor Installation And Wiring

    The maximum length of the resistor cable is 10 m. For protection against overheating, resistors with thermal circuit breakers (standard in ABB resistors) should be used. The circuit breakers should be wired to the ENABLE inputs of the brake choppers.

  • Page 226: Brake Circuit Commissioning

    The following is a wiring diagram example of the resistor connection. Brake chopper R– R– ° Brake resistor Brake circuit commissioning In the drive application program, overvoltage control of the drive must be disabled for correct operation of the brake chopper. This has been done at the factory for units with brake choppers.
  • Page 228 ABB Inc. ABB Oy AC Drives Automation Technologies P.O. Box 184 Drives & Motors FI-00381 HELSINKI 16250 West Glendale Drive FINLAND New Berlin, WI 53151 Telephone +358 10 22 11 +358 10 22 22681 Telephone 262 785-3200 Internet http://www.abb.com 800-HELP-365...

This manual is also suitable for:

Acs800-37-0100-3Acs800-37-0210-3Acs800-37-0070-3Acs800-37-0260-3Acs800-37-0320-3Acs800-37-0140-3 ... Show all

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