ABB ACS800-17 Hardware Manual

Acs800 55 to 2500 kw / 75 to 2800 hp

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ACS800

Hardware Manual

ACS800-17 Drives (55 to 2500 kW / 75 to 2800 hp)

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Summary of Contents for ABB ACS800-17

Page 1 ACS800 Hardware Manual ACS800-17 Drives (55 to 2500 kW / 75 to 2800 hp)
Page 2 List of related manuals Drive hardware manuals and guides ACS800-17 Drives (55 to 2500 kW / 75 to 2800 hp) 3AFE68397260 Hardware Manual Drive (inverter) firmware manuals and guides ACS800 Standard Control Program Firmware Manual 3AFE64527592 ACS800 System Control Program Firmware Manual...
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 • The brake control terminals (UDC+, UDC-, R+ and R- terminals) carry a dangerous DC voltage (over 500 V). • Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V) may be present on the relay outputs of the drive system. •...
Page 8 • Do not use the ramp which is supplied with the drive with heights over 50 mm (the standard plinth height of ABB cabinets). The ramp is designed for a plinth height of 50 mm. Support the top and...
Page 9: Grounding
• When removing a module which is equipped with wheels, pull the module carefully out of the cubicle along the ramp. Make sure that the wires do not catch. While pulling on the handle, keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back.
Page 10: Fibre Optic Cables
• Do not install a drive equipped with an EMC (line) filter to an ungrounded power system or a high resistance-grounded (over 30 ohms) power system. Note: • Power cable shields are suitable for equipment grounding conductors only when adequately sized to meet safety regulations. •...
Page 11: 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 12: 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 13: Table Of Contents
The ACS800-17 ........
Page 14 Door switches .............39 Main switch-disconnector (Q1 in frame size R6 to R8i) .
Page 15 Permanent magnet synchronous motor ..........68 Thermal overload and short-circuit protection .
Page 16 Input power connection – Frame R8i ..........86 Connection diagram .
Page 17 Parameters ............. 111 Default values of parameters with the ACS800-17 ....... 112 ACS800-17-specific parameters in the inverter control program .
Page 18 ACS800-17 frame sizes and power module types ........
Page 19 Providing feedback on ABB Drives manuals ........
Page 20: Table Of Contents
Table of contents...
Page 21: About This Manual
National Electrical Code and local codes are marked with (US). Common chapters for multiple products Some chapters in this manual apply to several products including the ACS800-17. Other product types may be mentioned in these chapters. Categorization according to the frame size...
Page 22: Contents
Safety instructions gives safety instructions for the installation, commissioning, operation and maintenance of the drive. About this manual introduces this manual. The ACS800-17 describes the drive. Mechanical installation instructs how to move, place and mount the drive. Planning the electrical installation provides advice on motor and cable selection, the protective functions of the drive, and cable routing.
Page 23: Installation And Commissioning Flowchart
For instructions on how to disconnect the EMC/ If the drive is about to be connected to an IT RFI filtering, contact your local ABB (ungrounded) system: representative. • check that the drive is not equipped with EMC/RFI...
Page 24: 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 25 DC link of the drive, or from the DC link of the drive to the network. With ACS800-17 drives of frame size R8i and above, the line-side converter is also called the (IGBT) supply unit or the ISU.
Page 26 About this manual...
Page 27: The Acs800-17
What this chapter contains This chapter describes the construction of the drive in short. The ACS800-17 The ACS800-17 is a four-quadrant, cabinet-mounted drive for controlling asynchronous AC induction motors and generators, and permanent magnet synchronous motors and generators. Cabinet line-up...
Page 28: Frame R6
Auxiliary voltage transformer Integrated line-side/motor-side converter module Input terminals (bottom cable entry/exit models) Input terminals (top cable entry/exit models) Output terminals (bottom cable entry/exit models) Output terminals (top cable entry/exit models) Control unit (RDCU) for motor-side converter Cabinet cooling fan The ACS800-17...
Page 29: Frame R7I
Cable entries for power and control cables (bottom cable entry/exit models) Cable entries for power and control cables (top cable entry/exit models) Switch fuse Auxiliary voltage transformer Line-side converter module LCL filter Motor-side converter module Input terminals Output terminals The ACS800-17...
Page 30: Frame R8I
Cooling fan for IGBT supply module Cooling fan for inverter module Auxiliary voltage transformer (accessible by opening the swing-out frame) Auxiliary voltage circuitry (relays etc.) *In larger drives, an air circuit breaker is used instead of the switch-disconnector/contactor combination. The ACS800-17...
Page 31: Swing-Out Frame
Remove screws (arrowed) to Swing-out frame open open swing-out frame Drive control unit (RDCU) with I/O terminal blocks Space for optional terminal block X2 I/O cable entries into Terminal block X1 swing-out frame Mounting rails for additional equipment The ACS800-17...
Page 32 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. The ACS800-17...
Page 33: Cabling Direction
Signal cable input/output – Top entry (IP21-42) Signal cable input/output – Top entry (IP54) Frame size R7i Description Input/Motor output – Bottom entry Input/Motor output – Top entry Signal cable input/output – Bottom entry Signal cable input/output – Top entry The ACS800-17...
Page 34 Standard output (top exit); at each inverter module Motor output – Bottom exit with common motor terminal cubicle (optional) Motor output – Top exit with common motor terminal cubicle (optional) Signal cable input/output – Bottom entry Signal cable input/output – Top entry The ACS800-17...
Page 35: 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 ACS800-17...
Page 36: Operation Principle
Intermediate DC link 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 ACS800-17...
Page 37: Motor-Side Converter
In the inverter modules, the optic link connects to the AINT board, the terminals of which are accessible through a hole on the front panel of the module. The ACS800-17...
Page 38: Controls
Controls Control interfaces of the drive The following diagram shows the control interfaces and I/O options of the drive. The ACS800-17...
Page 39: Door Switches
Other auxiliary voltages are on. Reset button RESET Resets an emergency stop, after which the supply unit can be started using the start switch. (Drive faults are reset via the drive control panel or serial communication) The ACS800-17...
Page 40: Control Panel
ISU 800 0490_3LR DRIVE IXXR7xxx ID-NUMBER 2 To scroll to ID number 1 ACS 800 0490_3MR ASXR7xxx ID-NUMBER 1 To verify the change to the motor-side converter -> 0.0 rpm I FREQ 0.00 Hz CURRENT 0.00 A POWER 0.00 % The ACS800-17...
Page 41: Fieldbus Control Of The Line-Side Converter
110 (value) 11.01 DC REF SELECT Dataset 123 (CH1) Dataset 123 (CH0) PARAM 23.01 95.08 LCU PAR1 SEL DC VOLT REF 95.09 LCU PAR2 SEL table 23.01 FIELD BUS MCW = Main Control Word MSW = Main Status Word The ACS800-17...
Page 42: Type Code
The type code contains information on the specifications and configuration of the drive. The first digits from left express the basic configuration (e.g. ACS800-17-0490-3). The optional selections are given thereafter, separated by + signs (e.g. +E202). The main selections are described below.
Page 43: Frame Sizes 2×R8I To 6×R8I
RDCO-03 DDCS Communication Option; CDP-312R Control Panel; EMC/RFI filtering for 2nd Environment; du/dt filtering; common mode filtering; Standard Control Program; bottom entry/exit of cables; coated circuit boards; set of English manuals. Size Refer to Technical data: ratings. The ACS800-17...
Page 44 M603 = 4 … 6.3 A (1, 2 or 4 pcs) M604 = 6.3 … 10 A (1, 2 or 4 pcs) M605 = 10 … 16 A (1 or 2 pcs) M606 = 17 … 25 A (1 pc) The ACS800-17...
Page 45 Q968 = Safe torque off (STO) with a safety relay Q971 = ATEX-certified safety function Special P902 = Customised (specified in Technical appendix on ordering) P904 = Extended warranty P913 = Special colour (specified in Technical appendix on ordering) The ACS800-17...
Page 46 The ACS800-17...
Page 47: 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 48: 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 49: 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 50: 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 51: 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 52: 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 53: 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 54: 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 55: 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 56: 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 57: 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 58: 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 59: 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 60: 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 61: 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 62 Mechanical installation...
Page 63: 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 64: Protecting The Motor Insulation And Bearings
The stress on motor insulation can be avoided by using optional ABB du/dt filters. du/dt filters also reduce bearing currents.
Page 65 Motor type Nominal mains Requirement for voltage (AC line Motor insulation ABB du/dt filter, insulated N-end bearing and ABB common mode voltage) system filter < 100 kW 100 kW < P <...
Page 66 For motors with higher rated output than what is stated for the particular frame size in EN 50347 (2001) and for IP 23 motors, the requirements of ABB random-wound motor series M3AA, M3AP, M3BP are given below. For other motor types, see the Requirements table above.
Page 67 Note 8: Calculating the rise time and the peak line-to-line voltage The peak line-to-line voltage at the motor terminals generated by the drive as well as the voltage rise time depend on the cable length. The requirements for the motor insulation system given in the table are “worst case”...
Page 68: Permanent Magnet Synchronous Motor
Permanent magnet synchronous motor Only one permanent magnet motor can be connected to the inverter output. It is recommended to install a safety switch between a permanent magnet synchronous motor and the motor cable. The switch is needed to isolate the motor during any maintenance work on the drive.
Page 69: Earth Fault (Ground Fault) Protection
Earth fault (Ground fault) protection Both the supply unit and the inverter unit are equipped with an internal earth fault protective function to protect the drive against earth faults in the drive, motor and motor cable. (This is not a personal safety or a fire protection feature.) Both earth fault protective functions can be disabled by a parameter.
Page 70: Prevention Of Unexpected Start-Up
Prevention of unexpected start-up The drive can be equipped with an optional Prevention of unexpected start-up function according to standards IEC/EN 60204-1:1997; ISO/DIS 14118:2000, EN 1037:1996, EN ISO 12100:2003, EN954-1:1996 and EN ISO 13849-2:2003. Note: The Prevention of unexpected start-up function is not SIL/PL classified. The function disables the control voltage of the power semiconductors of the drive output stage, thus preventing the motor-side converter from generating the voltage required to rotate the motor.
Page 71: Safe Torque Off
Safe torque off The drive supports the Safe torque off function according to standards EN 61800-5- 2:2007; EN ISO 13849-1:2008, IEC 61508, IEC 61511:2004 and EN 62061:2005. The function also corresponds to prevention of unexpected start-up of EN 1037. The Safe torque off function disables the control voltage of the power semiconductors of the drive output stage, thus preventing the inverter from generating the voltage required to rotate the motor.
Page 72: 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 73: 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 A separate PE conductor is required if the phase conductors, concentric or otherwise conductivity of the cable shield is less than 50% of the symmetrical PE conductor, overall shield) conductivity of a phase conductor.
Page 74: Motor Cable Shield
Motor cable shield To effectively suppress radiated and conducted radio-frequency emissions, the shield conductivity must be at least 1/10 of the phase conductor conductivity. The requirements are easily met with a copper or aluminium shield. The minimum requirement of the motor cable shield of the drive is shown below. It consists of a concentric layer of copper wires with an open helix of copper tape.
Page 75: 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 76: 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 77: 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 78: 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 79: 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 80 Planning the electrical installation...
Page 81: 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 82: Before Installation
Protective Earth conductor using a measuring voltage of 500 V DC. The insulation resistance of an ABB motor must exceed 100 Mohm (reference value at 25 °C or 77 °F). For the insulation resistance of other motors, please consult the manufacturer’s instructions.
Page 83: Emc Filter +E200
EMC filter +E200, disconnect the ground connection of the filter before connecting the drive to the supply network. For detailed instructions on how to do this, please contact your local ABB representative. See also section Compliance with EN 61800- 3:2004 on page 154.
Page 84: 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 85: 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 86: Input Power Connection - Frame R8I
Input power connection – Frame 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 99. 1.
Page 87: Input Power Connection - Frame 2×R8I And Up
Input power connection – Frame 2×R8i and up Connection diagram U< Connection procedure Note: Before making the cable connections, check that the tap settings of the auxiliary voltage transformer (T10, located in the auxiliary control cubicle) are correct in regard to the supply voltage. See instructions on page 99. 1.
Page 88: Grounding Of Shielded Single-Core Input Cables
Grounding of shielded single-core input cables Connect the cable shield to the PE busbar at the transformer side only and insulate the shield at the drive side. Motor connection – Frame R6 Connection diagram Connection procedure 1. Open the cabinet door. 2.
Page 89: 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 90: 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 1. Open the door of the input/output cubicle (see section Cabling direction starting on page 33). 2. Remove any shrouds that protect the output busbars and cable entries. 3.
Page 91: 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 chapter Dimensions. Connection diagram Inverter unit cubicle Connection procedure WARNING! Obey the safety instructions when you handle the heavy module! See...
Page 92 7. Provide support for the cables whenever necessary. 8. Insert the inverter module back into the cubicle as described in section Inserting the module into the cubicle on page 131. Electrical installation...
Page 93: 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 33). 2. Remove any shrouds that protect the output busbars and cable entries. 3.
Page 94: 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 chapter Dimensions. Connection diagram Inverter unit cubicle(s) WARNING! The cabling from all inverter modules to the motor must be physically...
Page 95: Connection Procedure
Connection procedure WARNING! Obey the safety instructions when you handle the heavy module! See section Power module replacement (Frame R8i and up) on page 127. Ignoring these instructions can cause physical injury or death, or damage to the equipment. 1. Extract each inverter module from the cubicle as described in section Extracting the module from the cubicle on page...
Page 96: 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 chapter Motor control and I/O board (RMIO). Supply unit control connections The supply unit is controlled using the local control devices optionally mounted on the cabinet door, i.e.
Page 97 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 98: 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 99: 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 100 Electrical installation...
Page 101: 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 ACS800 Standard Control 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 102: External Control Connections (Non-Us)
External control connections (non-US) External control cable connections to the RMIO board for the ACS800 Standard Control Program (Factory Macro) are shown below. For external control connections of other application macros and programs, see the appropriate Firmware Manual. Terminal block size: VREF- Reference voltage -10 V DC, 1 kohm <...
Page 103: External Control Connections (Us)
External control connections (US) External control cable connections to the RMIO board for the ACS800 Standard Control Program (Factory Macro US version) are shown below. For external control connections of other application macros and programs, see the appropriate Firmware Manual. Terminal block size: VREF- Reference voltage -10 V DC, 1 kohm <...
Page 104: Rmio Board Specifications
RMIO board specifications Analogue inputs With Standard Control 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 105: Relay Outputs
Maximum continuous current 2 A rms Isolation test voltage 4 kV AC, 1 minute DDCS fibre optic link With optional communication adapter module RDCO. Protocol: DDCS (ABB Distributed Drives Communication System) 24 V DC power input Voltage 24 V DC ± 10%...
Page 106 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 107: 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 ACS800-17. Installation checklist Check the mechanical and electrical installation of the drive before start-up. Go through the checklist below together with another person.
Page 108: Start-Up Procedure
Disconnect any unfinished or unchecked 230/115 V AC cables that lead from the terminal blocks to the outside of the equipment. For drive types ACS800-17-0640-3/0780-5/0790-7 and up: Locate the These drive types have two PPCS APBU-xx PPCS branching units. Enable memory backup battery on branching units, one for the supply each branching unit by setting actuator 6 of switch S3 to ON.
Page 109: 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. Inverter control program set-up...
Page 110: Acs800-17-Specific Parameters In The Igbt Supply Control Program
Check the direction of rotation of the motor. ACS800-17-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.
Page 111: Parameters
Parameters Name/Value Description T./FbEq Def. 16 SYSTEM CTR Parameter lock, parameter back-up etc. INPUTS 16.15 START MODE Selects start mode. EDGE LEVEL Starts converter by level of control command. Control command is selected by parameter 98.01 COMMAND SEL and 98.02 COMM. MODULE.
Page 112: Default Values Of Parameters With The Acs800-17
65535 Default values of parameters with the ACS800-17 When the IGBT Supply Control Program is loaded into the ACS800-17, the following parameters receive the default values given in the table below. Do not change the default values. If they are changed, the drive will not operate properly.
Page 113: Acs800-17-Specific Parameters In The Inverter Control Program
ACS800-17-specific parameters in the inverter control program The actual signals and parameters described in this section are included in the most commonly used inverter control program, ACS800 Standard Control Program. Terms and abbreviations Term Definition Actual signal Signal measured or calculated by the drive. Can be monitored by the user.
Page 114: The Inverter Control Program
Actual signals and parameters of the supply unit control program visible also in the inverter control program Name/Value Description FbEq Def. 09 ACTUAL SIGNALS Signals from the supply unit (line-side converter). 09.12 LCU ACT SIGNAL 1 Line-side converter signal selected by par. 95.08 LCU PAR1 SEL. 1 = 1 09.13 LCU ACT SIGNAL 2...
Page 115: 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 116: Reduced Run Capability
Consult your local ABB Service representative for more details on the maintenance. On the Internet, go to http://www.abb.com/drivesservices. Reduced run capability If one of the parallel-connected (frame R8i) inverter modules of an inverter unit must be taken out of the cabinet for service, it is possible to continue operation at reduced power using the remaining modules.
Page 117: Quick Connectors (Frame R8I And Up)
Quick connectors (Frame R8i and up) 1. Read and repeat the steps in section Safety instructions on page 115. 2. Open the cabinet doors. 3. Extract a supply module or inverter module from the cabinet. See section Power module replacement (Frame R8i and up) on page 127.
Page 118: Cooling Fans
Cooling fans Supply/Inverter module cooling fan replacement (Frame R6) 1. Read and repeat the steps in section Safety instructions on page 115. 2. Loosen the fastening screws of the fan housing. 3. Push the fan housing backwards. 4. Lift the fan housing up (out of the way). 5.
Page 119: 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 the new fan in reverse order. Maintenance...
Page 120: 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 the new fan in reverse order. Maintenance...
Page 121: Supply And Inverter Module Cooling Fan Replacement (Frame R8I And Up)
The actual lifespan of the fan 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 122: Lcl Filter Cooling Fan Replacement (Frame R8I And Up)
LCL filter cooling fan replacement (Frame R8i and up) The actual lifespan of the fan 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 123: Cabinet Fan Replacement (Frame R6)
Cabinet fan replacement (Frame R6) 1. Read and repeat the steps in section Safety instructions on page 115. 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 124: Cabinet Fan Replacement (Frame 2Xr8I And Up With Ip21-42)
Cabinet fan replacement (Frame 2xR8i and up with IP21-42) WARNING! Read and follow the instructions in chapter Safety instructions. Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Switch off the power to the unit and open the main disconnecting device. Close the grounding switch (option +F259) if there is one.
Page 125: 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 126: 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 127: Power Module Replacement (Frame R8I And Up)
They topple over easily if handled carelessly. • Do not use the ramp which is supplied with the drive with heights over 50 mm (the standard plinth height of ABB cabinets). The ramp is designed for a plinth height of 50 mm. Support the top and...
Page 128: Extracting The Module From The Cubicle
WARNING! Do not use the ramp which is supplied with the drive with heights over 50 mm (the standard plinth height of ABB cabinets). The ramp is designed for a plinth height of 50 mm. 9. Remove the two module fastening screws at the top.
Page 129 Maintenance...
Page 130 View from back: Maintenance...
Page 131: Inserting The Module Into The Cubicle
Inserting the module into the cubicle 1. Move the module close to the ramp, and then retract the support legs of the module. 2. Push the module up the ramp and back into the cubicle. WARNING! Keep your fingers away from the edge of the module front plate to avoid pinching them between the module and the cubicle.
Page 132 Maintenance...
Page 133: 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. Information on warnings and faults concerning the supply unit (line-side converter) are contained within the IGBT Supply Control Program Firmware Manual (3AFE68315735 [English]).
Page 134: 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 135: Technical Data
CE and other markings, and warranty information. IEC ratings The ratings for the ACS800-17 with a 50 Hz supply are given below. The symbols are described below the table. No-over-...
Page 136: Symbols
No-over- Light- Heavy-duty Heat dissi- Noise Nominal ratings load use overload use pation flow level ACS800-17 type cont.max cont.max ACS800-17-1640-5 1746 1884 2734 1400 1809 1300 1409 1000 10240 ACS800-17-2160-5 2304 2486 3608 1800 2387 1700 1860 1300 12800 Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V, or 690 V...
Page 137: Temperature 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 138: Nema Ratings
NEMA ratings The ratings for the ACS800-17 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 ACS800-17 type cont.max /min Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V or 480 V...
Page 139: Symbols
(460 or 575 V). Note: The ratings apply at an ambient temperature of 40 °C (104 °F). At lower temperatures, the ratings are higher. ACS800-17 frame sizes and power module types Supply module(s) used* LCL filter(s) used Inverter modules used*...
Page 140: Ac Fuses
Supply module(s) used* LCL filter(s) used Inverter modules used* ACS800-17 type Frame size Type Type Type ACS800-17-0780-5 2×R8i ACS800-104-0460-5+E205 ALCL-24-5 ACS800-104-0400-5+E205 ACS800-17-0870-5 2×R8i ACS800-104-0460-5+E205 ALCL-24-5 ACS800-104-0460-5+E205 ACS800-17-1140-5 2×R8i ACS800-104-0610-5+E205 ALCL-25-5 ACS800-104-0610-5+E205 ACS800-17-1330-5 3×R8i ACS800-104-0610-5+E205 ALCL-24-5 ACS800-104-0460-5+E205 ACS800-17-1640-5 3×R8i ACS800-104-0610-5+E205 ALCL-24-5...
Page 141 AC fuse information Drive type aR, IEC aR, UL Recognized Bussmann Mersen Bussmann Mersen 500 V ACS800-17-0070-5 170M3814 – 170M3014 – ACS800-17-0100-5 170M3815 – 170M3015 – ACS800-17-0120-5 170M3816 – 170M3016 – ACS800-17-0170-5 170M3817 – 170M3017 – ACS800-17-0210-5 170M5808 – 170M5008 –...
Page 142: 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 Mersen Bussmann 400 V ACS800-17-0060-3 … – – – – – – ACS800-17-0490-3 ACS800-17-0640-3 170M8552 6.9URD3PV1000...
Page 143: Input Power Connection
Input power connection Voltage (U 380/400/415 V AC 3-phase ± 10% for 400 V AC units 380/400/415/440/460/480/500 V AC 3-phase ± 10% for 500 V AC units 525/550/575/600/660/690 V AC 3-phase ± 10% for 690 V AC units Short-circuit withstand Units without grounding switch: Maximum allowable prospective short-circuit current is strength (IEC 60439-1) 65 kA when protected by the fuses given in the fuse tables.
Page 144 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 145: 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 146 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 147 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 148: Efficiency
Maximum recommended 100 m (328 ft). motor cable length Motor cables up to 300 m (984 ft) long are allowed for frames R6 and R7i, and up to 500 m (1640 ft) long for frames R8i and up, but then EMC filtering within the specified limits will not be realised.
Page 149: 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. Technical data...
Page 150: Tightening Torques For Power Connections
Tightening torques for power connections Screw size Torque M5 3.5 Nm (2.6 lbf.ft) M6 9 Nm (6.6 lbf.ft) M8 20 Nm (14.8 lbf.ft) M10 40 Nm (29.5 lbf.ft) M12 70 Nm (52 lbf.ft) M16 180 Nm (133 lbf.ft) Applicable standards The drive complies with the following standards.
Page 151: 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. The CE marking also verifies that the drive, in regard to its safety functions (such as Safe torque off), conforms with the Machinery Directive as a safety component. Compliance with the European Low Voltage Directive The compliance with the European Low Voltage Directive has been verified according to standards EN 60204-1 and EN 61800-5-1.
Page 152: Declaration Of Conformity
Declaration of Conformity Technical data...
Page 153 Technical data...
Page 154: Compliance With En 61800-3:2004
Compliance with EN 61800-3:2004 Definitions EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to operate without problems within an electromagnetic environment. Likewise, the equipment must not disturb or interfere with any other product or system within its locality. First environment includes establishments connected to a low-voltage network which supplies buildings used for domestic purposes.
Page 155: Category C4
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 156 Technical data...
Page 157: What This Chapter Contains
(5.1”) with top entry/exit models as well as units with cooling air intake through the bottom of the cabinet. • The measurements given apply to 6-pulse-input, non-UL/CSA units. For dimensions of 12-pulse-input or UL/CSA units, contact your local ABB representative. The tables are followed by example dimensional drawings.
Page 158: R8I
Input/Output Supply and Common Sine filter Line-up Net weight cubicle inverter motor cubicle width (kg approx.) unit cubicle terminal cubicle* 1200 300** 1500 1030 400** 1600 1200 *Added with filter option +E202 if option +E206 (sine filter) is not present. +H359 is not available without +E202.
Page 159: 4×R8I
4×R8i 1000 3800 3800 3380 1000 4100 4100 3460 1000 4200 4200 3455 1000 400* 3900 4500 3535 1000 1000 1000 3800 2300 6100 4360 1000 1000 1000 4100 2300 6400 4440 1000 1000 1000 1000 3800 3300 7100 4810 1000 1000 1000 1000 4100 3300...
Page 160: Frame R6
Frame R6 Dimensions...
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Page 162: Frame R7I
Frame R7i Dimensions...
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Page 167: Frame R7I With +E202/+E205/+H359
Frame R7i with +E202/+E205/+H359 Dimensions...
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Page 175: Frame R7I, Marine Construction (+C121)
Frame R7i, marine construction (+C121) Dimensions...
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Page 178: Frame R8I
Frame R8i Dimensions...
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Page 184: Frame R8I With +E202/+H359
Frame R8i with +E202/+H359 Dimensions...
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Page 186: Frame 2×R8I
Frame 2×R8i Dimensions...
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Page 196: Frame 3×R8I
Frame 3×R8i Dimensions...
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Page 202: Frame 4×R8I
Frame 4×R8i Dimensions...
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Page 208: Frame 5×R8I
Frame 5×R8i Dimensions...
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Page 220: Frame 6×R8I
Frame 6×R8i Dimensions...
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Page 236 Contact us...

ABB ACS800-17 Hardware Manual

Table of Contents

Table of Contents

About this Manual

The ACS800-17

Mechanical Installation

Planning the Electrical Installation

Electrical Installation

Motor Control and I/O Board (RMIO)

Installation Checklist and Start-Up

Maintenance

Fault Tracing

Technical Data

Quick Links

Chapters

Related Manuals for ABB ACS800-17

Summary of Contents for ABB ACS800-17