ABB ACS800 Hardware Manual
  1. Manuals
  2. Brands
  3. ABB Manuals
  4. Controller
  5. ACS 800 Series
  6. Hardware manual

ABB ACS800 Hardware Manual

Hide thumbs Also See for ACS800:
Table of Contents

Advertisement

Quick Links

See also: User Manual , Hardware Manual
ACS800
Hardware Manual
ACS800-01 Drives (0.55 to 200 kW)
ACS800-U1 Drives (0.75 to 200 HP)

Advertisement

Table of Contents
loading

Related Manuals for ABB ACS800

Summary of Contents for ABB ACS800

  • Page 1 ACS800 Hardware Manual ACS800-01 Drives (0.55 to 200 kW) ACS800-U1 Drives (0.75 to 200 HP)

  • Page 2: Acs800 Single Drive Manuals

    ACS800 Single Drive Manuals HARDWARE MANUALS (appropriate manual is included in the delivery) ACS800-01/U1 Hardware Manual 0.55 to 200 kW (0.75 to 200 HP) 3AFE64382101 (English) ACS800-01/U1/04 Marine Supplement 0.55 to 160 kW (0.75 to 200 HP) 3AFE68291275 (English) ACS800-11/U11 Hardware Manual 5.5 to 110 kW (7.5 to 125 HP) 3AFE68367883 (English) ACS800-31/U31 Hardware Manual 5.5 to110 kW (7.5 to 125 HP)
  • Page 3 ACS800-01 Drives 0.55 to 200 kW ACS800-U1 Drives 0.75 to 200 HP Hardware Manual 3AFE64382101 Rev J EN EFFECTIVE: 1.10.2008 © 2008 ABB Oy. All Rights Reserved.

  • Page 5: Safety Instructions

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

  • Page 6: Installation And Maintenance Work

    AGPS board (Prevention of Unexpected Start, ACS800-01/U1, ACS800-04/ 04M, ACS800-11/U11, ACS800-31/U31). • ACS800-02 with enclosure extension: The main switch on the cabinet door does not remove the voltage from the input busbars of the drive. Before working on the drive, isolate the whole drive from the supply.

  • Page 7: Grounding

    In addition, connect the cable shields to protective earth (PE) in order to meet safety regulations. ACS800-04 (45 to 560 kW) and ACS800-02 in first environment: make a 360° high frequency grounding of motor cable entries at the cabinet lead-through.

  • Page 8: Mechanical Installation And Maintenance

    Do not lift the unit by the front cover. Place the unit only on its back. ACS800-02, ACS800-04: The drive is heavy. Lift the drive by the lifting lugs only. Do not tilt the unit. The unit will overturn from a tilt of about 6 degrees.

  • Page 9: Printed Circuit Boards

    Printed circuit boards WARNING! Ignoring the following instructions can cause damage to the printed circuit boards: • The printed circuit boards contain components sensitive to electrostatic discharge. Wear a grounding wrist band when handling the boards. Do not touch the boards unnecessarily. Fibre optic cables WARNING! Ignoring the following instructions can cause equipment malfunction and damage to the fibre optic cables:...

  • Page 10: Operation

    Operation These warnings are intended for all who plan the operation of the drive or operate the drive. WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment: • 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 11: Permanent Magnet Motor

    Permanent magnet motor These are additional warnings concerning permanent magnet motor drives. Ignoring the instructions can cause physical injury or death, or damage to the equipment. Installation and maintenance work WARNING! Do not work on the drive when the permanent magnet motor is rotating. Also, when the supply power is switched off and the inverter is stopped, a rotating permanent magnet motor feeds power to the intermediate circuit of the drive and the supply connections become live.
  • Page 12 Safety instructions...

  • Page 13: Table Of Contents

    Providing feedback on ABB Drives manuals ........
  • Page 14 Delivery check .............28 Before installation .
  • Page 15 Selecting the control cables ............48 Relay cable .
  • Page 16 What this chapter contains ............73 Note on terminal labelling .
  • Page 17 Fuses ..............92 Frame sizes R2 to R4 .
  • Page 18 What this chapter contains ............141 Availability of brake choppers and resistors for the ACS800 ......141 Selecting the correct drive/chopper/resistor combination .

  • Page 19: About This Manual

    Technical data. The ACS800-01/U1 is manufactured in frame sizes R2 to R6. Categorization according to the + code The instructions, technical data and dimensional drawings which concern only certain optional selections are marked with + codes, e.g. +E202. The options included in the drive can be identified from the + codes visible on the type designation label of the drive.

  • Page 20: Contents

    The ACS800-01/U1 describes the drive. Mechanical installation instructs how to place and mount the drive.

  • Page 21: Installation And Commissioning Flowchart

    If the converter has been non-operational for equipment are present and correct. more than one year, the converter DC link capacitors need to be reformed. Ask ABB for Only intact units may be started up. instructions. If the drive is about to be connected to an IT...

  • Page 22: Product And Service Inquiries

    Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type code and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/drives...

  • Page 23: The Acs800-01/U1

    The ACS800-01/U1 What this chapter contains This chapter describes the operating principle and construction of the drive in short. The ACS800-01/U1 The ACS800-01/U1 is a wall mountable drive for controlling AC motors. Control panel CDP312R Heat sink Front cover Connection box...

  • Page 24: Type Code

    Type code The type code contains information on the specifications and configuration of the drive. The first digits from left express the basic configuration (e.g. ACS800-01- 0006-5). The optional selections are given thereafter, separated by + signs (e.g. +E202). The main selections are described below. Not all selections are available for all types.

  • Page 25: Main Circuit And Control

    AC voltage to DC voltage capacitor bank energy storage which stabilizes the intermediate circuit DC voltage IGBT inverter converts the DC voltage to AC voltage and vice versa. The motor operation is controlled by switching the IGBTs. The ACS800-01/U1...

  • Page 26: Printed Circuit Boards

    Motor control 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 current is measured for earth fault protection. The ACS800-01/U1...

  • Page 27: Mechanical Installation

    Mechanical installation Unpacking the unit The drive is delivered in a box that also contains: • plastic bag containing: screws (M3), clamps and cable lugs (2 mm , M3) for grounding the control cable screens • connection box (screws, clamps and vibration dampers with +C131 included) •...

  • Page 28: Delivery Check

    Delivery check Check that there are no signs of damage. Before attempting installation and operation, check the information on the type designation label of the drive to verify that the unit is of the correct type. The label includes an IEC and NEMA rating, UL, C-UL, CSA and CE markings, a type code and a serial number, which allow individual recognition of each unit.

  • Page 29: Free Space Around The Unit

    Free space around the unit Required free space around the drive to enable cooling air flow, service and maintenance is shown below in millimetres and [inches]. When mounting IP 55 units above one another, leave 200 mm (7.9 in.) free space above and below the unit. 50 [2.0] 200 [7.9] 50 [2.0]...

  • Page 30: Mounting The Drive On The Wall

    IP 55 (UL type 12) marine applications (+C132) of frame sizes R4 to R6 See ACS800-01/U1 Marine Supplement [3AFE68291275 (English)]. Units with vibration dampers (+C131) See ACS800-01/U1 Vibration Damper Installation Guide [3AFE68295351 (English)]. UL 12 units Install the hood delivered with the drive 50 mm (2.0 in.) above the top of unit.

  • Page 31: Cabinet Installation

    Cabinet installation For better cooling, it is recommended to remove the front cover if the unit is installed into a cabinet. The required distance between parallel units is five millimetres (0.2 in.) in installations without the front cover. The cooling air entering the unit must not exceed +40 °C (+104 °F).

  • Page 32: Unit Above Another

    Unit above another Lead the out-coming cooling air away from the unit above. Example max.+40 °C (+104 °F) Mechanical installation...

  • Page 33: 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 34: 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 35: Requirements Table

    Requirements table The following table shows how to select the motor insulation system and when an optional ABB du/dt filter, insulated N-end (non-driven end) motor bearings and ABB common mode filters are required. The motor manufacturer should be consulted regarding the construction of the motor insulation and additional requirements for explosion-safe (EX) motors.
  • Page 36 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 < 350 kW > 350 kW frame size > IEC 315 frame size <...
  • Page 37 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 38: Permanent Magnet Synchronous Motor

    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 39: Supply Connection

    Supply connection Disconnecting device (disconnecting means) Install a hand-operated input disconnecting device (disconnecting means) between the AC power source and the drive. The disconnecting device must be of a type that can be locked to the open position for installation and maintenance work. To meet the European Union Directives, according to standard EN 60204-1, Safety of Machinery, the disconnecting device must be one of the following types: •...

  • Page 40: Thermal Overload And Short-Circuit Protection

    Thermal overload and short-circuit protection Thermal overload protection of the drive and the input and motor cables The drive protects itself and the input and motor cables against thermal overload when the cables are dimensioned according to the nominal current of the drive. No additional thermal protection devices are needed.

  • Page 41: Protection Against Short-Circuit Inside The Drive Or In The Supply Cable

    ABB with the ACS800 can be used. Fuses must be used with other circuit breakers. Contact your local ABB representative for the approved breaker types and supply network characteristics.

  • Page 42: Ground Fault Protection

    This is not a personal safety or a fire protection feature. The ground fault protective function can be disabled with a parameter, refer to the appropriate ACS800 Firmware Manual. The EMC filter of the drive includes capacitors connected between the main circuit and the frame.

  • Page 43: Selecting The Power Cables

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

  • Page 44: 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 45: 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 V AC cable is accepted for up to 500 V AC.

  • Page 46: Equipment Connected To The Motor Cable

    Stop the drive and wait for the motor to stop before opening a contactor between the output of the drive and the motor when the DTC control mode is selected. See the appropriate ACS800 control program firmware manual for the required parameter settings. Otherwise, the contactor will be damaged. In scalar control, the contactor can be opened with the drive running.

  • Page 47: Protecting The Relay Output Contacts And Attenuating Disturbances In Case Of Inductive Loads

    Protecting the relay output contacts and attenuating disturbances in case of inductive loads Inductive loads (relays, contactors, motors) cause voltage transients when switched off. The relay contacts on the RMIO board are protected with varistors (250 V) against overvoltage peaks. In spite of this, it is highly recommended to equip inductive loads with noise attenuating circuits [varistors, RC filters (AC) or diodes (DC)] in order to minimize the EMC emission at switch-off.

  • Page 48: 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. Planning the electrical installation...

  • Page 49: Connection Of A Motor Temperature Sensor To The Drive I/O

    3. An external thermistor relay is used. The insulation of the relay must be rated for the same voltage level as the main circuit of the drive. For connection, see ACS800 Firmware Manual. Installation sites above 2000 metres (6562 feet) WARNING! Protect against direct contact when installing, operating and servicing the RMIO board wiring and optional modules attached to the board.

  • Page 50: Control Cable Ducts

    A diagram of the cable routing is shown 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 230 V 230 V (120 V)

  • Page 51: Electrical Installation

    Electrical installation What this chapter contains This chapter describes the electrical installation procedure of the drive. WARNING! The work described in this chapter may only be carried out by a qualified electrician. Follow the Safety instructions on the first pages of this manual. Ignoring the safety instructions can cause injury or death.

  • Page 52: Checking The Insulation Of The Assembly

    Disconnect the EMC filter capacitors of selections +E202 and +E200 before connecting the drive to an ungrounded system. For detailed instructions on how to do this, please contact your local ABB distributor. WARNING! If a drive with EMC filter selection +E202 or +E200 is installed on an IT...

  • Page 53: Connecting The Power Cables

    Connecting the power cables Diagram Drive OUTPUT INPUT UDC+ V1 W1 V2 W2 (PE) (PE) External brake For alternatives, see resistor Planning the electrical Motor installation: Disconnecting device (disconnecting means) 1), 2) Grounding of the motor cable shield at the motor end If shielded cable is used (not required but For minimum radio frequency interference: recommended), use a separate PE cable (1) or a...

  • Page 54: Conductor Stripping Lengths

    Conductor stripping lengths Strip the conductor ends as follows to fit them inside the power cable connection terminals. Frame size Stripping length R2, R3 0.39 R4, R5 0.63 1.10 Allowed wire sizes, tightening torques Technical data: Cable entries. Wall installed units (European version) Power cable installation procedure 1.
  • Page 55 Connection box (IP 21) Fastening hooks Back plate Fastening screws 360 degrees grounding clamp Grommet Motor cable entry Input cable entry Brake resistor cable entry Control cable entry Bottom plate Fasten the control cables between these plates with cable Cover ties Frame sizes R2 to R4 UDC+...
  • Page 56 Frame size R5 UDC+ UDC- Electrical installation...
  • Page 57 Frame size R6: Cable lug installation [16 to 70 mm (6 to 2/0 AWG) cables] Remove the screw terminals. Fasten the cable lugs to the remaining bolts with M10 nuts. Isolate the ends of the cable lugs with Connection plate insulating tape or fastening screws shrink tubing.

  • Page 58: Wall Installed Units (Us Version)

    Wall installed units (US version) 1. Remove the front cover (in frame size R6 the lower front cover) by releasing the retaining clip with a screw driver and lifting the cover from the bottom outwards. 2. Make the cable entry holes in the gland box by breaking off the suitable knock-out plates with a screw driver.

  • Page 59: Warning Sticker

    Wire size Compression lug Crimping tool MCM/AWG Manufacturer Type Manufacturer Type No. of crimps Burndy YAV6C-L2 Burndy MY29-3 Ilsco CCL-6-38 Ilsco ILC-10 Burndy YA4C-L4BOX Burndy MY29-3 Ilsco CCL-4-38 Ilsco MT-25 Burndy YA2C-L4BOX Burndy MY29-3 Ilsco CRC-2 Ilsco IDT-12 Ilsco CCL-2-38 Ilsco MT-25 Burndy...

  • Page 60: Frame Size R5

    Protect the RMIO board terminals X25 to X27 against contact when input voltage exceeds 50 V AC. Frame size R5 Cover the power cable terminals as follows: 1. Cut holes for the installed cables into the clear plastic shroud. 2. Press the shroud onto the terminals. Removal of the shroud with a screw driver: Electrical installation...

  • Page 61: Frame Size R6

    Frame size R6 Cover the power cable terminals as follows: 1. Cut holes for the installed cables into the clear plastic shroud in cable lug installations. 2. Press the shroud onto the terminals. View of cable terminal installation Removal of the shroud by lifting up with a screw driver from the corner: Electrical installation...

  • Page 62: Connecting The Control Cables

    Connecting the control cables Lead the cable through the control cable entry (1). Connect the control cables as described below. Connect the conductors to the appropriate detachable terminals of the RMIO board [refer to chapter Motor control and I/O board (RMIO)].
  • Page 63 Frame sizes R5 and R6 View of frame size R6 Control panel Optional module 2 Optional module 1 DDCS communication option module 3: RDCO Place the warning sticker here Control cable Detachable connection terminals (pull up) grounding: see section Terminal for optional degrees Prevention of Unexpected grounding...

  • Page 64: Degrees Grounding

    360 degrees grounding Insulation Double-shielded cable Single-shielded cable When the outer surface of the shield is covered with non-conductive material • Strip the cable carefully (do not cut the grounding wire and the shield) • Turn the shield inside out to expose the conductive surface. •...

  • Page 65: Cabling Of I/O And Fieldbus Modules

    Cabling of I/O and fieldbus modules Module As short as possible Shield Note: The RDIO module does not include a terminal for cable shield grounding. Ground the pair cable shields here. Pulse encoder module cabling As short as possible Note1: If the encoder is of unisolated type, ground the encoder cable at the drive end only.

  • Page 66: Fastening The Control Cables And Covers

    Fastening the control cables and covers When all control cables are connected, fasten them together with cable ties. Units with a connection box: fasten the cables to the entry plate with cable ties. Units with a gland box: tighten the clamping nuts of the cable glands. Fasten the connection box cover.

  • Page 67: Installation Of Agps Board (Prevention Of Unexpected Start, +Q950)

    Installation of AGPS board (Prevention of Unexpected Start, +Q950) What this chapter contains This chapter describes • electrical installation of the optional Prevention of Unexpected Start function (+Q950) of the drive. • specifications of the board. Prevention of Unexpected Start (+Q950) The optional Prevention of Unexpected Start function includes an AGPS board which is connected to the drive and an external power supply.
  • Page 68 Connect the AGPS board as follows: • Remove the enclosure cover by undoing the fixing screws (1). • Ground the unit via the bottom plate of the enclosure or via terminal X1:1 of the AGPS board. • Connect the cable delivered with the kit between terminal block X2 of the AGPS board (2) and drive terminal block X41.

  • Page 69: Circuit Diagram

    Circuit diagram This circuit diagram shows how the AGPS-11 kit is installed. Installation of AGPS board (Prevention of Unexpected Start, +Q950)

  • Page 70: Dimensional Drawing

    Dimensional drawing The dimensional drawing of the AGPS board is shown below. $)( Installation of AGPS board (Prevention of Unexpected Start, +Q950)

  • Page 71: Agps-11C Board Specifications

    AGPS-11C board specifications Nominal input voltage 115...230 V AC ±10% Nominal input current 0.1 A (230 V) / 0.2 A (115 V) Nominal frequency 50/60 Hz Max. external fuse 16 A X1 terminal sizes 3 x 2.5 mm Output voltage 15 V DC ±0.5 V Nominal output current 0.4 A...
  • Page 72 Installation of AGPS board (Prevention of Unexpected Start, +Q950)

  • Page 73: 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. Note on terminal labelling Optional modules (Rxxx) may have identical terminal designations with the RMIO board.

  • Page 74: 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 control macros and programs, see the appropriate Firmware Manual. RMIO RMIO VREF- Reference voltage -10 V DC, 1 kohm <...

  • Page 75: 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 control macros and programs, see the appropriate Firmware Manual.

  • Page 76: 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 = 200 kohm).

  • Page 77: Relay Outputs

    Maximum continuous current 2 A rms Insulation test voltage 4 kV AC, 1 minute DDCS fibre optic link With optional communication adapter module RDCO. Protocol: DDCS (ABB Distributed Drives Communication System) 24 V DC power input Voltage 24 V DC ± 10%...
  • Page 78 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 79: Installation Checklist

    Installation checklist Checklist Check the mechanical and electrical installation of the drive before start-up. Go through the checklist below together with another person. Read the Safety instructions on the first pages of this manual before you work on the unit. Check MECHANICAL INSTALLATION The ambient operating conditions are allowed.
  • Page 80 Installation checklist...

  • Page 81: Maintenance

    Ignoring the safety instructions can cause injury or death. Maintenance intervals If installed in an appropriate environment, the drive requires very little maintenance. This table lists the routine maintenance intervals recommended by ABB. Maintenance Interval Instruction...

  • Page 82: Heatsink

    See the appropriate ACS800 firmware manual for an actual signal which indicates the hours of usage of the fan. For resetting the running time signal after a fan replacement, please contact ABB.

  • Page 83: Fan Replacement (R4)

    Fan replacement (R4) 1. Loosen the screws that fasten the fan mounting plate to the frame. 2. Push the fan mounting plate to the left and pull it out. 3. Disconnect the fan power cable. 4. Undo the screws that fasten the fan to the fan mounting plate. 5.

  • Page 84: Fan Replacement (R5)

    Fan replacement (R5) 1. Undo the fastening screws of the swing-out frame. 2. Open the swing-out frame. 3. Disconnect the cable. 4. Undo the fastening screws of the fan. 5. Install the new fan in reverse order. Bottom view Maintenance...

  • Page 85: Fan Replacement (R6)

    Fan replacement (R6) To remove the fan, undo the fixing screws. Disconnect the cable. Install the new fan in reverse order. Note: In -0205-3 and 0255-5 units, access the fan through the opening in the support frame when changing the fan. Bottom view Additional fan There is an additional cooling fan in all IP 55 units and most IP 21 units.

  • Page 86: Replacement (R4, R5)

    It is not possible to predict a capacitor failure. Capacitor failure is usually followed by a mains fuse failure or a fault trip. Contact ABB if capacitor failure is suspected. Replacements for frame size R4 and up are available from ABB. Do not use other than ABB specified spare parts.

  • Page 87: Leds

    LEDs This table describes LEDs of the drive. Where When the LED is lit RMIO board * Drive in fault state Green The power supply on the board is OK. Control panel mounting platform Drive in fault state (with type code selection +0J400 Green The main +24 V power supply for the control panel and the only)
  • Page 88 Maintenance...

  • Page 89: Technical Data

    CE and other markings and warranty policy. IEC data Ratings The IEC ratings for the ACS800-01 with 50 Hz and 60 Hz supplies are given below. The symbols are described below the table. ACS800-01 size Nominal...
  • Page 90 ACS800-01 size Nominal Light-overload Heavy-duty use Frame Air flow Heat overload ratings size dissipation cont.max cont.max Three-phase supply voltage 380 V, 400 V or 415 V -0003-3 -0004-3 -0005-3 10.8 -0006-3 10.9 13.8 10.2 -0009-3 13.9 17.6 12.7 -0011-3 -0016-3...

  • Page 91: Symbols

    ACS800-01 size Nominal Light-overload Heavy-duty use Frame Air flow Heat overload ratings size dissipation cont.max cont.max Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V -0011-7 11.5 -0016-7 -0020-7 18.5 -0025-7 18.5 -0030-7 18.5...

  • Page 92: Derating

    Note 3: Larger fuses than the recommended ones must not be used. Note 4: Fuses from other manufacturers can be used if they meet the ratings and the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table. ACS800-01 Input Fuse...
  • Page 93 ACS800-01 Input Fuse size current Manufacturer Type IEC size Three-phase supply voltage 380 V, 400 V or 415 V -0003-3 ABB Control OFAF000H10 -0004-3 ABB Control OFAF000H10 -0005-3 ABB Control OFAF000H10 -0006-3 ABB Control OFAF000H16 -0009-3 ABB Control OFAF000H16 -0011-3...

  • Page 94: Frame Sizes R5 And R6

    = transformer impedance (ohm) = transformer impedance (%) = transformer rated voltage (V) = nominal apparent power of the transformer (kVA) = cable reactance (ohm). Calculation example Drive: • ACS800-01-0075-3 • supply voltage Transformer: • rated power S = 600 kVA •...
  • Page 95 + (22.19 mohm + 13.94 mohm) 2 · The calculated short-circuit current 2.7 kA is higher than the minimum short-circuit current of the drive gG fuse type OFAF00H160 (2400 A). -> The 500 V gG fuse (ABB Control OFAF00H160) can be used. Technical data...

  • Page 96: Fuse Tables For Frame Sizes R5 And R6

    Fuse tables for frame sizes R5 and R6 Standard gG fuses ACS800-01 size Input Min. Fuse current short- circuit current Manufacturer Type IEC size Three-phase supply voltage 208 V, 220 V, 230 V or 240 V -0025-2 1050 34500 ABB Control...

  • Page 97: Ultrarapid (Ar) Fuses

    Standard gG fuses ACS800-01 size Input Min. Fuse current short- circuit current Manufacturer Type IEC size * maximum total I t value for 550 V or 690 V minimum short-circuit current of the installation Note 1: See also Planning the electrical installation: Thermal overload and short-circuit protection.
  • Page 98 Ultrarapid (aR) fuses ACS800-01 size Input Min. Fuse current short- circuit current Manufacturer Type IEC size -0060-7 4650 Bussmann 170M1567 -0070-7 8500 Bussmann 170M1568 -0100-7 16000 Bussmann 170M1569 -0120-7 15000 Bussmann 170M3815 -0145-7 1520 68500 Bussmann 170M3818 DIN1* -0175-7 1520...

  • Page 99: Quick Guide For Selecting Between Gg And Ar Fuses

    The table below is a short cut in selecting between gG and aR fuses. The combinations (cable size, cable length, transformer size and fuse type) in the table fulfil the minimum requirements for the proper operation of the fuse. ACS800-01 size Cable type Supply transformer minimum apparent power S...

  • Page 100: Cable Types

    Selection of smaller fuses improves the protection, but may also affect the fuse life time and lead to unnecessary operation of the fuses. In case of any uncertainty regarding the drive protection, please contact your local ABB. Cable types The table below gives copper and aluminium cable types for different load currents.

  • Page 101: Cable Entries

    Cable entries Brake resistor, mains and motor cable terminal sizes (per phase), accepted cable diameters and tightening torques are given below Frame U1, V1, W1, U2, V2, W2, R+, R Earthing PE size Wire size Max. cable Ø Cable Ø Tightening Wire size Tightening...

  • Page 102: Nema Data

    NEMA data Ratings The NEMA ratings for the ACS800-U1 with 60 Hz supplies are given below. The symbols are described below the table. For sizing, derating and 50 Hz supplies, see IEC data on page 89. ACS800-U1 size Normal use...

  • Page 103: Symbols

    ACS800-U1 size Normal use Heavy-duty use Frame Air flow Heat size dissipation /min BTU/Hr Three-phase supply voltage 525 V, 575 V, 600 V -0011-7 11.5 1050 -0016-7 1200 -0020-7 15/20 **** 15 15** 1550 -0025-7 20** 1850 -0030-7 25/30 **** 25...

  • Page 104: Fuses

    Note 4: Fuses from other manufacturers can be used if they meet the ratings and the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table. ACS800-U1 type Frame size Input Fuse...

  • Page 105: Cable Types

    ACS800-U1 type Frame size Input Fuse current Manufacturer Type UL class Three-phase supply voltage 525 V, 575 V, 600 V -0011-7 Bussmann JJS-20 -0016-7 Bussmann JJS-20 -0020-7 Bussmann JJS-30 -0025-7 Bussmann JJS-30 -0030-7 Bussmann JJS-45 -0040-7 Bussmann JJS-45 -0050-7 Bussmann...

  • Page 106: Cable Entries

    Cable Entries Brake resistor, input and motor cable (per phase) terminal sizes, accepted cable diameters and tightening torques are given below Frame U1, V1, W1, U2, V2, W2, R+, R Earthing PE size Wire size Knock-out hole Ø Tightening Wire size Tightening (UL type 1) torque...

  • Page 107: Input Power Connection

    Input power connection Voltage (U 208/220/230/240 V AC 3-phase ± 10% for 230 V AC units 380/400/415 V AC 3-phase ± 10% for 400 V AC units 380/400/415/440/460/480/500 V AC 3-phase ± 10% for 500 V AC units 525/550/575/600/660/690 V AC 3-phase ± 10% for 690 V AC units Short-circuit withstand Maximum allowable prospective short-circuit current is 65 kA when protected by fuses strength (IEC 60439-1)

  • Page 108: Cooling

    Cooling Method Internal fan, flow direction from bottom to top. Free space around the unit See chapter Mechanical installation. Degrees of protection IP 21 (UL type 1) and IP 55 (UL type 12). Without connection box and front cover, the unit must be protected against contact according to IP 2x [see chapter Electrical installation: Cabinet installation (IP 21, UL type 1)].

  • Page 109: 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. Applicable standards The drive complies with the following standards. The compliance with the European Low Voltage Directive is verified according to standards EN 61800-5-1 and EN 60204-1.

  • Page 110: 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 2004/108EC). Definitions EMC stands for Electromagnetic Compatibility.

  • Page 111: 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 112: 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 requirements and specific test methods), mandated by the Trans- Tasman Electromagnetic Compatibility Scheme.

  • Page 113: Second Environment (Drive Of Category C3)

    WARNING! A drive of category C4 is not intended to be used on a low-voltage public network which supplies domestic premises. Radio frequency interference is expected if the drive is used on such a network. Marine type approvals See ACS800-01/U1/04/U4 Marine Supplement [3AFE68291275 (English)]. Technical data...

  • Page 114: Ul/Csa Markings

    UL/CSA markings The ACS800-01 and ACS800-U1 units of UL type 1 are C-UL US listed and CSA marked. The drive is suitable for use on a circuit capable of delivering not more than 100 kA rms symmetrical amperes at the drive nominal voltage (600 V maximum for 690 V units) when protected by fuses given...
  • Page 115 If you have any questions concerning your ABB drive, please contact the local distributor or ABB office. The technical data, information and specifications are valid at the time of printing. The manufacturer reserves the right to modifications without prior notice.
  • Page 116 Technical data...
  • Page 117 Dimensional drawings Dimensional drawings of the ACS800-01 are shown below. The dimensions are given in milllimetres and [inches]. Dimensional drawings...

  • Page 118: Frame Size R2 (Ip 21, Ul Type 1)

    Frame size R2 (IP 21, UL type 1) Dimensional drawings...

  • Page 119: Frame Size R2 (Ip 55, Ul Type 12)

    Frame size R2 (IP 55, UL type 12) Dimensional drawings...

  • Page 120: Frame Size R3 (Ip 21, Ul Type 1)

    Frame size R3 (IP 21, UL type 1) Dimensional drawings...

  • Page 121: Frame Size R3 (Ip 55, Ul Type 12)

    Frame size R3 (IP 55, UL type 12) Dimensional drawings...

  • Page 122: Frame Size R4 (Ip 21, Ul Type 1)

    Frame size R4 (IP 21, UL type 1) Dimensional drawings...

  • Page 123: Frame Size R4 (Ip 55, Ul Type 12)

    Frame size R4 (IP 55, UL type 12) Dimensional drawings...

  • Page 124: Frame Size R5 (Ip 21, Ul Type 1)

    Frame size R5 (IP 21, UL type 1) Dimensional drawings...

  • Page 125: Frame Size R5 (Ip 55, Ul Type 12)

    Frame size R5 (IP 55, UL type 12) Dimensional drawings...

  • Page 126: Frame Size R6 (Ip 21, Ul Type 1)

    Frame size R6 (IP 21, UL type 1) Dimensional drawings...

  • Page 127: Frame Size R6 (Ip 21, Ul Type 1), -205-3 And -255-5 Units

    Frame size R6 (IP 21, UL type 1), -205-3 and -255-5 units Note: Only measurements that differ from those of the standard Frame size R6 (IP 21, UL type 1) are given below. Dimensional drawings...

  • Page 128: Frame Size R6 (Ip 55, Ul Type 12)

    Frame size R6 (IP 55, UL type 12) Dimensional drawings...
  • Page 129 Frame size R6 (IP 55, UL type 12) -0205-3 and -0255-5 units Supplementary page 3AUA0000057717 2009-04-16...

  • Page 130: Dimensional Drawings (Usa)

    Dimensional drawings (USA) Dimensional drawings of the ACS800-U1 are shown below. The dimensions are given in milllimetres and [inches]. Dimensional drawings...

  • Page 131: Frame Size R2 (Ul Type 1, Ip 21)

    Frame size R2 (UL type 1, IP 21) Dimensional drawings...

  • Page 132: Frame Size R2 (Ul Type 12, Ip 55)

    Frame size R2 (UL type 12, IP 55) Dimensional drawings...

  • Page 133: Frame Size R3 (Ul Type 1, Ip 21)

    Frame size R3 (UL type 1, IP 21) Dimensional drawings...

  • Page 134: Frame Size R3 (Ul Type 12, Ip 55)

    Frame size R3 (UL type 12, IP 55) Dimensional drawings...

  • Page 135: Frame Size R4 (Ul Type 1, Ip 21)

    Frame size R4 (UL type 1, IP 21) Dimensional drawings...

  • Page 136: Frame Size R4 (Ul Type 12, Ip 55)

    Frame size R4 (UL type 12, IP 55) Dimensional drawings...

  • Page 137: Frame Size R5 (Ul Type 1, Ip 21)

    Frame size R5 (UL type 1, IP 21) Dimensional drawings...

  • Page 138: Frame Size R5 (Ul Type 12, Ip 55)

    Frame size R5 (UL type 12, IP 55) Dimensional drawings...

  • Page 139: Frame Size R6 (Ul Type 1, Ip 21)

    Frame size R6 (UL type 1, IP 21) Dimensional drawings...

  • Page 140: Frame Size R6 (Ul Type 1, Ip 21) -0205-3 And -0255-5 Units

    Frame size R6 (UL type 1, IP 21) -0205-3 and -0255-5 units Note: Only measurements that differ from those of the standard Frame size R6 (UL type 1, IP 21) are given below. Dimensional drawings...

  • Page 141: Frame Size R6 (Ul Type 12, Ip 55)

    Frame size R6 (UL type 12, IP 55) Dimensional drawings...
  • Page 142 Frame size R6 (UL type 12, IP 55) -0205-3 and -0255-5 units Supplementary page 3AUA0000057717 2009-04-16...

  • Page 143: Resistor Braking

    This chapter describes how to select, protect and wire brake choppers and resistors. The chapter also contains the technical data. Availability of brake choppers and resistors for the ACS800 Frame R2 and R3 drives and 690 V units of frame size R4 have a built-in brake chopper as standard equipment.

  • Page 144: Optional Brake Chopper And Resistor(S) For The Acs800-01/U1

    Optional brake chopper and resistor(s) for the ACS800-01/U1 The nominal ratings for dimensioning the brake resistors for the ACS800-01 and ACS800-U1 are given below at an ambient temperature of 40 °C (104 °F). ACS800-01 type Braking power Brake resistor(s)
  • Page 145 ACS800-01 type Braking power Brake resistor(s) of the chopper ACS800-U1 type and the drive Type brcont Rcont (kW) (ohm) (kJ) (kW) 400 V units -0003-3 SACE08RE44 -0004-3 SACE08RE44 -0005-3 SACE08RE44 -0006-3 SACE08RE44 -0009-3 SACE08RE44 -0011-3 SACE15RE22 -0016-3 SACE15RE22 -0020-3 SACE15RE22...
  • Page 146 ACS800-01 type Braking power Brake resistor(s) of the chopper ACS800-U1 type and the drive Type brcont Rcont (kW) (ohm) (kJ) (kW) 690 V units -0011-7 SACE08RE44 -0016-7 SACE08RE44 -0020-7 SACE08RE44 -0025-7 SACE08RE44 -0030-7 SACE15RE22 -0040-7 22/33 SACE15RE22 -0050-7 SACE15RE13 -0060-7...

  • Page 147: Protection Of Frame Sizes R2 To R5 (Acs800-01/U1)

    Note: If an external brake chopper (outside the drive module) is used, a main contactor is always required. A thermal switch (standard in ABB resistors) is required for safety reasons. The cable must be shielded and not longer than the resistor cable.

  • Page 148: Brake Circuit Commissioning

    RMIO:X22 or X2: X22 +24VD +24VD Thermal switch DGND1 (standard in ABB re- Θ sistors) DGND2 DIIL For other control programs, the thermal switch may be wired to a different digital input.

  • Page 149: External +24 V Power Supply For The Rmio Board Via Terminal X34

    External +24 V power supply for the RMIO board via terminal X34 What this chapter contains This chapter describes how to connect an external +24 V power supply for the RMIO board via terminal X34. For the current consumption of the RMIO board, see chapter Motor Control and I/O Board (RMIO).

  • Page 150: Connecting +24 V External Power Supply

    Connecting +24 V external power supply 1. Break off the tab covering the +24 VDC power input connector with pliers. 2. Lift the connector upwards. 3. Disconnect the wires from the connector (keep the connector for later use). 4. Isolate the ends of the wires individually with insulating tape. 5.
  • Page 151 RMIO board RMIO board Connection of a two-way Connection of a three-way connector connector External +24 V power supply for the RMIO board via terminal X34...
  • Page 152 External +24 V power supply for the RMIO board via terminal X34...
  • Page 154 ABB Oy ABB Inc. ABB Beijing Drive Systems Co. Ltd. AC Drives Automation Technologies No. 1, Block D, A-10 Jiuxianqiao Beilu P.O. Box 184 Drives & Motors Chaoyang District FI-00381 HELSINKI 16250 West Glendale Drive Beijing, P.R. China, 100015 FINLAND...

This manual is also suitable for:

Acs800-01Acs800-u1

Table of Contents