1. Manuals
  2. Brands
  3. ABB Manuals
  4. DC Drives
  5. ACS850-04 series
  6. Hardware manual

ABB ACS850-04 Hardware Manual

Drive modules (400 to 560 kw, 450 to 700 hp)
Hide thumbs Also See for ACS850-04:
Table of Contents

Advertisement

Quick Links

Download this manual See also: Hardware Manual
ACS850
Hardware Manual
ACS850-04 Drive Modules (400 to 560 kW, 450 to 700 hp)
Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com

Advertisement

Table of Contents
loading

Related Manuals for ABB ACS850-04

Summary of Contents for ABB ACS850-04

  • Page 1 ACS850 Hardware Manual ACS850-04 Drive Modules (400 to 560 kW, 450 to 700 hp) Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 2 You can find manuals and other product documents in PDF format on the Internet. See section Document library on the on the inside of the back cover. For manuals not available in the Document library, contact your local ABB Internet representative.
  • Page 3 ACS850-04 Drive Modules 400 to 560 kW (450 to 700 hp) Hardware Manual 3AUA0000081249 Rev A EN EFFECTIVE: 2011-03-11 © 2011 ABB Oy. All Rights Reserved. Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 4 Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 5 Update Notice This notice concerns the following ACS850-04 Hardware Code: 3AUA0000102679 Rev A Manuals: Valid: From 29.6.2011 until the release of Rev B of the manual Code Revision Language Contents: Unpacking drawings for the additional 3AUA0000081249 English boxes in the transport package of the drive module and...

  • Page 6: List Of Related Manuals

    Ramp package contents Screw package Fasrtening bracket Telescopic extraction and insertion ramp PE terminal Cardboard box Pedestal guide plate Top guide plate Support Install the PE terminal (4) and assembly support (8) as shown below. M8×16 Hex M4×12 Torx Update Notice Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 7 Output power cabling panel (option +H381) package contents Paper fill Grounding busbar to be connected to the input power cabling panel and the drive module Cardboard tray Top cardboard cover Support Bands Plastic bag Output power cabling panel - 3A Side guides for Rittal cabinet assembly - 3A Install the grounding busbar (2) as shown below.
  • Page 8 Input power cabling panel (option +H381) package contents Screw package Paper fill Input power cabling panel Cardboard tray Top cardboard cover Support Bands Plastic bag - 3A - 3A Update Notice Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 9: Table Of Contents

    Table of contents List of related manuals ............2 Table of contents Safety instructions What this chapter contains .
  • Page 10 HXR and AMA motors ..........51 ABB motors of types other than M2_, M3_, HX_ and AM_ ..... .51 Resistor braking of the drive .
  • Page 11 Routing the cables ............. . 56 Separate control cable ducts .
  • Page 12 Connecting the control cables ........... . .83 Flowchart of the control cable installation process (external control unit) .
  • Page 13 Fans ............... 110 Replacing the circuit board compartment cooling fan .
  • Page 14 Providing feedback on ABB Drives manuals ........

  • Page 15: 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 16: Safety In Installation And Maintenance

    Safety in installation and maintenance Electrical safety These warnings are intended for all who work on the drive, motor cable or motor. WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment: • Only qualified electricians are allowed to install and maintain the drive. Never work on the drive, motor cable or motor when main power is applied.

  • Page 17: Grounding

    Grounding These instructions are intended for all who are responsible for the grounding of the drive. WARNING! Ignoring the following instructions can cause physical injury, death, increased electromagnetic interference and equipment malfunction: Ground the drive, motor and adjoining equipment to ensure personnel safety in •...

  • Page 18: Permanent Magnet Motor Drives

    Permanent magnet motor drives These are additional warnings concerning permanent magnet motor drives. WARNING! Ignoring the instructions can cause physical injury or death, or damage to the equipment. • 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 19: General Safety

    General safety These instructions are intended for all who install and service the drive. WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment: - Lift the drive module using the lifting lugs attached to the top and base of the •...

  • Page 20: Fiber Optic Cables

    - Push the drive module into the cabinet and pull it from the cabinet carefully preferably with help from another person as shown below. Keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back.

  • Page 21: Printed Circuit Boards

    Printed circuit boards WARNING! Ignoring the following instructions can cause damage to the printed circuit boards: Wear a grounding wrist band when handling the boards. Do not touch the • boards unnecessarily. The printed circuit boards contain components sensitive to electrostatic discharge. Safe start-up and operation General safety These warnings are intended for all who plan the operation of the drive or operate...
  • Page 22 Safety instructions Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 23: Introduction To The Manual

    Introduction to the 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 24: Categorization By Option Code

    If the drive module has been non-operational Only intact units may be started up. for more than one year, the converter DC link capacitors need to be reformed. Ask ABB for instructions. Check the installation site. Fasten the base of the...
  • Page 25 Task Route the cables. (page 56) Routing the cables Check the insulation of the supply cable, the motor (page Checking the insulation of the assembly and the motor cable and the resistor cable (if present). Units with optional cabling panels (+H318) Installing the mechanical accessories into the (page 73) •...

  • Page 26: Terms And Abbreviations

    Task Connect the external control cables to the drive (page 83) Connecting the control cables control unit. Control cable connection procedure of units +P905), page with internal control unit (option Check the installation. (page 99) Installation checklist Commission the drive. (page 103) Start-up Commission the brake chopper (if used).
  • Page 27 High-threshold logic IGBT Insulated gate bipolar transistor; a voltage-controlled semiconductor type widely used in inverters due to their easy controllability and high switching frequency. Input/Output The control unit of the drive module. The external I/O control signals are connected to the JCU, or optional I/O extensions mounted on it. JGDR Gate driver board JINT...
  • Page 28 Introduction to the manual Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 29: Operation Principle And Hardware Description

    This chapter describes the operating principle and construction of the drive module in short. Product overview The ACS850-04 is a drive module for controlling asynchronous AC induction motors and permanent magnet synchronous motors. The main circuit of the drive module is shown below.

  • Page 30: Layout

    Layout The components of the standard unit are shown below. W1, V1, U1 W2, V2, U2 Item Description Drive module Lifting lugs Fastening bracket Input cable connection busbars and optional DC+ and DC- busbars (+H356) Circuit board compartment Power supply and fiber optic cables to be connected to the external control unit Output cable connection busbars and optional brake resistor connection busbars (+D150) PE terminal Control cable duct...
  • Page 31 Item Description Base fastening srews Handle for pulling the drive module out of the cabinet Pedestal guide plate Telescopic extraction and insertion ramp Top guide plate Optional common mode filter (+E208) Control unit (JCU) Control unit with front cover Control unit with front cover removed Control cable clamp plate Operation principle and hardware description Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 32 The drive module and optional selections are shown below: control unit and control panel variations and cabling panels. Item Description Drive module Input power cabling panel fastened to the drive module Output power cabling panel fastened to the drive module Front cover.
  • Page 33 The control unit layout is shown below (cover assembly and protective coverings of the slots removed). External 24 V power input Relay outputs +24VD Digital inputs Digital input/outputs Slots 1 and 2 for optional I/O extension Analog inputs and encoder/resolver interface modules Analog outputs Drive-to-drive link...

  • Page 34: Power Connections And Control Interfaces

    Power connections and control interfaces The diagram shows the power connections and control interfaces of the drive module. XPOW XRO1…3 XD24 Slot 1 XDIO XD2D XSTO Slot 2 Slot 3 t° UDC+ UDC- Slot 1 and I/O extension modules (FIO-01, FIO-11, FIO-21) 1) For intormation on the default Slot 2 and/or encoder or resolver interface modules...

  • Page 35: External Control Unit Connection Cables

    The cables for connecting the drive module and control panel to the control unit are shown below. See sections Connecting the external control unit to the drive module (page 85) and (page 97) for the actual connections. Connecting a PC ACS850-04 JRIB APOW 2560 mm (8.4 ft) JINT JGDR 3 m (9.8 ft)

  • Page 36: Type Designation Key

    The first digits from left express the basic configuration. The optional selections are given thereafter, separated by plus signs, eg, +E210. The main selections are described below. Not all selections are available for all types. For more information, refer to ACS850-04 Ordering Information (3AXD00000579470), available on request. Code...
  • Page 37 Code Description Option codes (plus codes) Resistor braking D150 Brake chopper and brake resistor connection busbars, and R+ and R- terminals in the power cabling panel (+H381) if the panel is ordered Filters E205 du/dt filter E208 Common mode filter. Includes three extension busbars to the drive module output busbars with units without option +H381.
  • Page 38 Code Description Paper manuals. Note: The delivered manual set may include manuals in English if the translation is not available. R700 English R701 German R702 Italian R703 Dutch R704 Danish R705 Swedish R706 Finnish R707 French R708 Spanish R709 Portuguese R711 Russian R712...

  • Page 39: Planning The Cabinet 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. Basic requirements for the cabinet Use a cabinet which: •...

  • Page 40: Layout Examples, Door Closed

    Layout examples, door closed Layout examples for IP22 and IP54 cabinets are shown below (input power cable lead-through from top and motor cable lead-through from bottom). IP22 IP54 Roof air flow viewed from top (IP54) 1a Air inlet for the drive module 1b Air inlet for the other equipment 2a Air outlet for the drive module 2b Air outlet for the other equipment...

  • Page 41: Layout Examples, Door Open

    Layout examples, door open Layout examples for units in IP22 and IP54 cabinets are shown below. Optional cabling panels (+H318) are not used. . IP22 IP54 Air flow through the drive module (side view) Supporting frame of the cabinet IP54 Air baffles that separate the cool and hot areas (leak- proof lead-throughs) Cabinet grounding busbar (PE)

  • Page 42: Arranging The Grounding Inside The Cabinet

    • Always fasten the drive module from its fastening points to the cabinet . For details, see the module installation instructions. WARNING! Do not fasten the cabinet by electric welding. ABB does not assume any liability for damages caused by electric welding as the welding circuit may damage electronic circuits in the cabinet.

  • Page 43: Planning The Cabinet Placement On A Cable Channel

    Planning the cabinet placement on a cable channel Note the following when planning to place the cabinet on a cable channel: • The cabinet structure must be sturdy enough. If the whole cabinet base will not be supported from below, the cabinet weight will lie on the sections that the floor carries.
  • Page 44 • 360° high frequency grounding of the cable shields at the cable lead-throughs improves the EMC shielding of the cabinet. • 360° high frequency grounding of the motor cable shields at their entries is recommended. The grounding can be implemented by a knitted wire mesh screening as shown below.

  • Page 45: Planning The Grounding Of The Cable Shields At The Cabinet Lead-Through

    Planning the grounding of the cable shields at the cabinet lead-through Follow the principle shown below when planning the grounding of the cable shields at the cabinet lead-through. To power cable terminals Cable shield PE (ground) terminal of the cabinet, cabling panel or drive module Stripped part of the cable EMC sleeve...
  • Page 46 • Leave enough free space around the components to ensure sufficient cooling. Observe the minimum clearances given for each component. For the required free space around the drive module, see page 43. • Also ventilate the heat dissipated by cables and other additional equipment. •...

  • Page 47: Preventing The Recirculation Of Hot Air

    Preventing the recirculation of hot air Prevent hot air circulation outside the cabinet by leading the outcoming hot air away from the area where the inlet air to the cabinet is taken. Possible solutions are listed below: • gratings that guide air flow at the air inlet and outlet •...

  • Page 48: Free Space At Top With Air Inlet Gratings In The Cabinet Door

    20 mm (0.79 in.) free space is required at the left-hand side of the module. Other installation positions Contact your local ABB representative. Planning the placement of the control panel Note the following alternatives when planning the placement of the control panel: •...

  • Page 49: Planning The Use Of The Cubicle Heaters

    Planning the use of the cubicle heaters Use a cubicle heater if there is a risk of condensation in the cabinet. Although the primary function of the heater is to keep the air dry, it may also be required for heating at low temperatures.
  • Page 50 Planning the cabinet installation Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 51: 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 52: Protecting The Motor Insulation And Bearings

    Protecting the motor insulation and bearings The drive employs modern IGBT inverter technology. Regardless of frequency, the drive output comprises pulses of approximately the drive DC bus voltage with a very short rise time. The pulse voltage can almost double at the motor terminals, depending on the attenuation and reflection properties of the motor cable and the terminals.

  • Page 53: Requirements Table

    Requirements table The following table shows how to select the motor insulation system and when optional ABB du/dt filters, insulated N-end (non-drive end) motor bearings and ABB common mode filters are required. Failure of the motor to fulfil the following requirements or improper installation may shorten motor life or damage the motor bearings and voids the warranty.

  • Page 54: Explosion-Safe (Ex) Motors

    Motor type Nominal AC line Requirement for voltage Motor insulation ABB du/dt filter, insulated N-end bearing and system ABB common mode filter < 350 kW or frame > 350 kW or frame size > IEC 315 size > IEC 400 <...

  • Page 55: 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 IP23 motors, the requirements of ABB random-wound motor series (for example M3AA, M3AP, M3BP) are given below. For non-ABB motor types, see the above.

  • Page 56: Sine Filters

    Û du/dt ------------ - (1/μs) Û du/dt ------------ - (1/μs) l (m) l (m) Motor cable length Craph for calculating the rise time of units with du/dt filter Craph for calculating the rise time of units without du/dt filter Sine filters Sine filters protect the motor insulation system.

  • Page 57: Typical Power Cable Sizes

    A four-conductor system is allowed for input cabling, but shielded symmetrical cable is recommended. To operate as a protective conductor, the shield conductivity requirements according to IEC 60439-1 are shown below when the protective conductor is made of the same metal as the phase conductors: Cross-sectional area of the phase Minimum cross-sectional area of the conductors...

  • Page 58: Typical Power Cable Sizes (Us)

    Typical power cable sizes (US) Cable sizing is based on NEC Table 310-16 for copper wires, 75 °C (167 °F) wire insulation at 40 °C (104 °F) ambient temperature. Not more than three current- carrying conductors in raceway or cable or earth (directly buried). For other conditions, dimension the cables according to local safety regulations, appropriate input voltage and the load current of the drive.

  • Page 59: 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 or copper wire.

  • Page 60: Selecting The Control Cables

    Control panel cable length and type In remote use, the cable connecting the control panel to the drive must not exceed 3 meters (10 ft). The cable type tested and approved by ABB is used in control panel option kits.
  • Page 61 Where control cables must cross power cables ensure that they are arranged at an angle as near to 90 degrees as possible. Do not run extra cables through the drive. The cable trays must have good electrical bonding to each other and to the grounding electrodes.

  • Page 62: Separate Control Cable Ducts

    Separate control cable ducts 230 V 230 V (120 V) (120 V) 24 V 24 V Not allowed unless the 24 V cable is Lead 24 V and 230 V (120 V) control insulated for 230 V (120 V) or insulated cables in separate ducts inside the with an insulation sleeving for 230 V cabinet.

  • Page 63: Implementing Thermal Overload And Short-Circuit Protection

    Implementing thermal overload and short-circuit protection Protecting the drive and input power cable in short-circuits Protect the drive with fuses and the input cable with fuses or a circuit breaker as shown below: Size the fuses or circuit breaker at the distribution board according to local regulations for the input cable protection.

  • Page 64: Protecting The Drive And The Input Power And Motor Cables Against Thermal Overload

    Protecting the drive and the input power and motor cables against thermal overload 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 65: Implementing The Emergency Stop Function

    Implementing the Emergency stop function For safety reasons, install the emergency stop devices at each operator control station and at other operating stations where emergency stop may be needed. Note: Pressing the stop key ( ) on the control panel of the drive does not generate an emergency stop of the motor or separate the drive from dangerous potential.
  • Page 66 ACS850-04 XSTO:1 +24 V XSTO:2 XSTO:3 XSTO:4 UDC+ U2/V2/W2 UDC- 1 Activation switch: • The contacts of the activation switch must open/close within 200 ms of each other. • The maximum cable length between the drive and the activation switch is 25 m (82 ft) WARNING! The Safe torque off function does not disconnect the voltage of the main and auxiliary circuits from the drive.

  • Page 67: Implementing The Atex-Certified Safe Motor Disconnection Function (Option +Q971)

    Implementing the ATEX-certified Safe motor disconnection function (option +Q971) With option +Q971, the drive provides ATEX-certified safe motor disconnection without contactor using the drive Safe torque off function. For more information, see ACS850 ATEX-certified Safe disconnection function application guide (3AUA0000074343 [English]). Implementing the Power loss ride-through function Implement the power loss ride-through function as follows: 1.

  • Page 68: Implementing A Safety Switch Between The Drive And Motor

    Implementing a safety switch between the drive and motor It is recommended to install a safety switch between the permanent magnet synchronous motor and the drive output. The switch is needed to isolate the motor during any maintenance work on the drive. Using a contactor between the drive and the motor Arrange the control of the output contactor by applying one of the alternatives described below.

  • Page 69: Example Bypass Connection

    Example bypass connection An example bypass connection is shown below. Switch Description Drive main switch Bypass circuit breaker Drive main contactor Bypass contactor Drive output contactor Drive main contactor on/off control Motor power supply selection (drive or direct-on-line) Start when motor is connected direct-on-line Stop when motor is connected direct-on-line Planning the electrical installation Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 70: Switching The Motor Power Supply From Drive To Direct-On-Line

    Switching the motor power supply from drive to direct-on-line 1. Stop the drive and the motor with the drive control panel (drive in the local control mode) or the external stop signal (drive in the remote control mode). 2. Open the main contactor of the drive with S11. 3.

  • Page 71: Connecting A Motor Temperature Sensor To The Drive I/O

    230 V AC 230 V AC 24 V DC 1) Relay outputs; 2) Varistor; 3) RC filter; 4) Diode Connecting 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.
  • Page 72 Planning the electrical installation Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 73: Installation

    Always follow the general rules given in this chapter and local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches local laws and/or other regulations. Note 1: The drive module can also be installed in other than Rittal TS 8 cabinets.

  • Page 74: Safety

    Note 2: With input and motor cables of size 4 × 240 mm per phase, DC cables cannot be lead to the terminals of the input cabling panel through the input cabling panel lead-throughs. Lead the DC cables then through the cabinet roof directly to the terminals.

  • Page 75: Moving And Unpacking The Unit

    Moving and unpacking the unit WARNING! Follow the safety instructions, page 12. Ignoring the instructions can cause physical injury or death, or damage to the equipment Move the transport package by pallet truck to the installation site. Unpack the package as follows: •...

  • Page 76: Checking The Delivery

    2. Measure the insulation resistance between each phase conductor and the 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 77: Brake Resistor And Resistor Cable

    Brake resistor and resistor cable Check the insulation of the brake resistor assembly (if present) as follows: 1. Check that the resistor cable is connected to the resistor, and disconnected from the drive output terminals R+ and R-. 2. At the drive end, connect the R+ and R- conductors of the resistor cable together. Measure the insulation resistance between the conductors and the PE conductor by using a measuring voltage of 1 kV DC.
  • Page 78 Installation Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 79: Connecting The Power Cables

    Connecting the power cables WARNING! Follow the safety instructions, page 12. Ignoring the instructions can cause physical injury or death, or damage to the equipment Connection diagram (PE) (PE) ACS850-04 V1 W1 UDC+ V1 W1 UDC+ INPUT OUTPUT V2 W2...
  • Page 80 For alternatives, see section Selecting the supply disconnecting device (disconnecting on page In the mounting example of this chapter, the disconnecting device is not means) in the same cubicle with the drive module. If a shielded cable is used (not required but recommended) and the conductivity of the shield is <...

  • Page 81: Input Cable Connection Procedure

    Input cable connection procedure WARNING! Follow the instructions in chapter instructions. Ignoring the Safety instructions can cause physical injury or death, or damage to the equipment. 1. Lead the cables into the inside of the cabinet. It is recommended to apply 360° grounding of the cable shields at the lead-through plate.

  • Page 82: Motor Cable Connection Procedure

    Motor cable connection procedure WARNING! Follow the instructions in chapter instructions. Ignoring the Safety instructions can cause physical injury or death, or damage to the equipment. 1. Lead the cables into the inside of the cabinet. Ground the cable shield 360° at the lead-through plate.

  • Page 83: Dc Connection

    The UDC+ and UDC– terminals are intended for common DC configurations of a number of drives, allowing regenerative energy from one drive to be utilised by the other drives in the motoring mode. Contact your local ABB representative for further instructions.

  • Page 84: Mounting The Drive Module Into The Cabinet

    Mounting the drive module into the cabinet WARNING! Follow the safety instructions, page 12. Ignoring the instructions can cause physical injury or death, or damage to the equipment. Handle the drive module carefully. Make sure that the module does not fall down when moving it on the floor and during installation and maintenance work: Open the support legs by pressing each leg a little down and turning it aside (1, 2).
  • Page 85 Installation Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 86: Assembly Drawing Of Fastening The Drive Module To The Cabinet

    Assembly drawing of fastening the drive module to the cabinet Installation Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 87: Removing The Protective Covering From The Module Air Outlet

    Removing the protective covering from the module air outlet WARNING! Remove the protective covering from the top of the drive module after the installation. If the covering is not removed, the cooling air cannot flow freely through the module and the drive will run to overtemperature. Connecting the control cables Flowchart of the control cable installation process (external control unit) Step...

  • Page 88: Removing The Cover Assembly Of The External Control Unit

    Removing the cover assembly of the external control unit The cover assembly needs to be removed before the installation of optional modules and the connection of control cabling. Follow this procedure to remove the cover assembly. The numbers refer to the illustrations below. 1.

  • Page 89: Fastening The Control Cable Clamp Plate

    Fastening the control cable clamp plate Fasten the control cable clamp plate either to the top or base of the control unit with four screws as shown below. 0.7 N·m (6.2 lbf·in) Connecting the external control unit to the drive module WARNING! Handle the fiber optic cables with care.
  • Page 90 JRIB JRIB APOW RXD = receiver TXD = transmitter 3AUA0000038989 Installation Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 91: Mounting The External Control Unit

    Mounting the external control unit The drive control unit can be fastened on a mounting plate through the fastening holes in its back or by using a DIN rail. Mounting the external control unit to wall 1. Fasten the fastening screws in the wall. 2.

  • Page 92: Mounting The External Control Unit Vertically On A Din Rail

    Mounting the external control unit vertically on a DIN rail 1. Fasten the latch (A) to the back of the control unit with four screws. 2. Click the control unit to the rail as shown below (B). 3aua0000038989 Mounting the control unit horizontally on a DIN rail 1.

  • Page 93: Installing Optional Modules

    Installing optional modules Mechanical installation Optional modules such as a fieldbus adapters, an I/O extensions and the pulse encoder interfaces are inserted in the optional module slot on the control unit. See page for the available slots. 1. Remove the control unit cover. 2.

  • Page 94: Connecting The Control Cables To The Terminals Of The Control Unit

    Connecting the control cables to the terminals of the control unit 1. Route the cables to the control unit as shown below. 1.5 N·m (13 lbf·in) 2. Ground the shields of the control cables at the clamp plate. The shields should be continuous as close to the terminals of the control unit as possible.
  • Page 95 directly at both ends if they are in the same ground line with no significant voltage drop between the end points.Tighten the screws to secure the connection. 3. Connect the conductors to the appropriate detachable terminals of the control unit. See section page Use shrink tubing or Default I/O connection diagram,...

  • Page 96: Default I/O Connection Diagram

    Default I/O connection diagram XPOW Notes: +24VI External power input […] denotes default setting with ACS850 24 V DC, 1.6 A Standard Control Program (Factory macro). See Firmware Manual for other XRO1, XRO2, XRO3 macros. Relay output RO1 [Ready] *Total maximum current: 200 mA 250 V AC / 30 V DC The wiring shown is for demonstrative purposes only.

  • Page 97: Jumpers

    Jumpers DI/DIO grounding selector (located between XD24 and XDI) – Determines whether the DIGND (ground for digital inputs DI1…DI5) floats, or if it is connected to DIOGND (ground for DI6, DIO1 and DIO2). See the JCU isolation and grounding diagram on page 121.

  • Page 98: External Power Supply For The Jcu Control Unit (Xpow)

    External power supply for the JCU Control Unit (XPOW) External +24 V (minimum 1.6 A) power supply for the control unit can be connected to terminal block XPOW. Using an external supply is recommended if • the application requires fast start after connecting the drive to the main supply •...

  • Page 99: Drive-To-Drive Link (Xd2D)

    WARNING! As the inputs pictured above are not insulated according to IEC 60664, the connection of the motor temperature sensor requires double or reinforced insulation between motor live parts and the sensor. If the assembly does not fulfil the requirement, •...

  • Page 100: Safe Torque Off (Xsto)

    Safe torque off (XSTO) For the drive to start, both connections (OUT1 to IN1, and OUT2 to IN2) must be closed. By default, the terminal block has jumpers to close the circuit. Remove the jumpers before connecting an external Safe torque off circuitry to the drive. See page 61.

  • Page 101: Connecting A Pc

    Connecting a PC Connect the PC to the drive control unit as follows:. NDPA-0x NDPC-12 Installation Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 102 Installation Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 103: Installation Checklist

    Installation checklist What this chapter contains This chapter contains a list for checking the mechanical and electrical installation of the drive. Installation checklist Go through the checklist below together with another person. WARNING! Follow the safety instructions, page 12. Ignoring the instructions can cause physical injury or death, or damage to the equipment Check that …...
  • Page 104 Check that … Connection of cables to devices, terminal blocks and drive module circuit boards: • Cables are connected to terminals tight enough by pulling the cable. • Cable termination on terminals chaining is done correctly. • Bare conductors are not too far outside the terminal causing an insufficient clearance or loss of shielding against contact.
  • Page 105 Check that … The supply voltage matches the nominal input voltage of the drive. Check the type designation label. The input power cable has been connected to the appropriate terminals, the phase order is right, and the terminals have been tightened. (Pull the conductors to check.) Appropriate AC fuses and main disconnector have been installed.
  • Page 106 Installation checklist Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 107: Start-Up

    Start-up What this chapter contains This chapter refers to the start-up instructions of the cabinet-installed drive. Start-up procedure 1. Ensure that the installation of the drive has been checked according to the checklist in chapter and that the motor and driven Installation checklist, equipment are ready for start.
  • Page 108 Start-up Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 109: Fault Tracing

    Fault tracing What this chapter contains This chapter describes the fault tracing possibilities of the drive. LEDs This table describes LEDs of the drive module. Where When the LED is lit JINT board V204 (green) +5 V voltage of the board is OK. V309 (red) Not in use.
  • Page 110 Fault tracing Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 111: Maintenance

    Installation. The other maintenance instructions are general. 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 Instruction Every year Checking main cooling fan and Maintenance if needed.

  • Page 112: Cabinet

    Replace with a new CR 2032 battery. Consult your local ABB Service representative for more details on the maintenance. On the Internet, go to ABB website. Cabinet Cleaning the interior of the cabinet WARNING! Follow the safety instructions, page 12. Ignoring the instructions can cause physical injury or death, or damage to the equipment.

  • Page 113: Heatsink

    Heatsink The module heatsink fins pick up dust from the cooling air. The drive runs into overtemperature warnings and faults if the heatsink is not clean. Cleaning the interior of the heatsink WARNING! Follow the safety instructions, page 12. Ignoring the instructions can cause physical injury or death, or damage to the equipment.

  • Page 114: Fans

    For resetting the running time signal after a fan replacement, please contact ABB. Replacement fans are available from ABB. Do not use other than ABB specified spare parts. Replacing the circuit board compartment cooling fan WARNING! Follow the safety instructions, page 12.

  • Page 115: Replacing The Main Cooling Fans

    Replacing the main cooling fans WARNING! Follow the safety instructions, page 12. Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Remove the drive module out of the cabinet as described in section Replacing the on page 112.

  • Page 116: Replacing The Drive Module

    Replacing the drive module WARNING! Follow the safety instructions, page 12. Ignoring the instructions can cause physical injury or death, or damage to the equipment. Handle the drive module carefully. Make sure that the module does not fall down when moving it on the floor and during installation and maintenance work: Open the support legs by pressing each leg a little down and turning it aside (1, 2).
  • Page 117 8. Pull the drive module carefully out of the cabinet preferably with help from another person. 9. Install the new module in reverse order to the above. Maintenance Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 118: Capacitors

    It is not possible to predict a capacitor failure. The capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. Contact ABB if a capacitor failure is suspected. Replacements are available from ABB. Do not use other than ABB specified spare parts.

  • Page 119: Technical Data

    Note: To achieve the rated motor power given in the table, the rated current of the drive must be higher than or equal to the rated motor current. The DriveSize dimensioning tool available from ABB is recommended for selecting the drive, motor and gear combination for the required motion profile.

  • Page 120: Ambient Temperature Derating

    Ambient temperature derating In the temperature range +40…55 °C (+104…131 °F), the rated output current is derated by 1% for every added 1 °C (1.8 °F) as follows: 1.00 0.85 +40 °C +55 °C +104 °F +131 °F Altitude derating At altitudes from 1000 to 4000 m (3300 to 13123 ft) above sea level, the derating is 1% for every 100 m (328 ft).

  • Page 121: Dimensions, Weights And Free Space Requirements

    Dimensions, weights and free space requirements Drive type Weight 1 Weight 2 ACS850-04 -710A-5 1662 1710 -807A-5 1662 1710 -875A-5 1662 1710 Drive type Weight 1 Weight 2 ACS850-04 -710A-5 65.44 67.33 12.01 12.96 20.00 20.39 -807A-5 65.44 67.33 12.01 12.96...

  • Page 122: Units With Optional Common Mode Filter(+E208)

    Units with optional common mode filter(+E208) The additonal busbars are included in the delivery of units with optional common mode filter (+E208). The output busbars of the drive module can be enhanced with the additonal busbars in units without optional cabling panels (no +H381). Then, the maximum accepted cable size is 4 ×...

  • Page 123: Electrical Power Network Specification

    Category C3 may not be fulfilled. Brake resistor connection data See page 139. DC connection data Drive module type Capacitance (mF) ACS850-04-710A-5 ACS850-04-807A-5 1033 ACS850-04-875A-5 1120 Technical data Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 124: Control Unit (Jcu-11) Connection Data

    Control unit (JCU-11) connection data 24 V (±10%) DC, 1.6 A Power supply Supplied from the power unit of the drive, or from an external power supply through connector XPOW (pitch 5 mm, wire size 2.5 mm Connector pitch 5 mm, wire size 2.5 mm Relay outputs RO1…RO3 250 V AC / 30 V DC, 2 A (XRO1 …...
  • Page 125 Connector pitch 3.5 mm, wire size 1.5 mm Analog inputs AI1 and AI2 Current input: –20…20 mA, R 100 ohm (XAI:4 … XAI:7). Voltage input: –10…10 V, R : 200 kohm Current/voltage input mode Differential inputs, common mode ±20 V selection by jumpers.

  • Page 126: Efficiency

    Efficiency Approximately 98% at nominal power level Degree of protection Without optional cabling panels IP00 ( (UL type open). IP20 (UL type open) with optional cabling panels (+H381). Ambient conditions Environmental limits for the drive are given below. The drive is to be used in a heated, indoor, controlled environment.

  • Page 127: 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 128: 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. Compliance with the European Low Voltage Directive The compliance with the European Low Voltage Directive has been verified according to standards EN 61800-5-1 and EN 60204-1.

  • Page 129: 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 130 Technical data Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 131: Dimension Drawings

    Dimension drawings What this chapter contains This chapter contains dimension drawings of the drive modules with optional parts for Rittal TS 8 cabinet assembly. Dimension drawings Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 132: Drive Module Dimensions

    Drive module dimensions Dimension drawings Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 133: Drive Module Dimensions With Optional Cabling Panels (+H381)

    Drive module dimensions with optional cabling panels (+H381) Dimension drawings Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 134 Dimension drawings Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 135: Cabling Panels (Option +H381) Installed Into A Rittal Ts 8 Cabinet

    Cabling panels (option +H381) installed into a Rittal TS 8 cabinet Dimension drawings Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 136 Dimension drawings Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 137: Example Circuit Diagrams

    Example circuit diagrams What this chapter contains This chapter shows an example circuit diagram for a cabinet-installed drive module. Example circuit diagrams Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 138: Example Circuit Diagram

    Example circuit diagram This diagram is an example for the main wiring of a drive cabinet. Note that the diagram includes components which are not included in a basic delivery (* plus code options, ** other options, *** to be acquired by the customer). Example circuit diagrams Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 139: Resistor Braking

    Energy consumption by the resistor losses lowers the voltage until the resistor can be disconnected. Hardware description The resistors available from ABB as add-on kits are built in an IP20 metal frame. 4×SAFUR resistors are connected in parallel. Planning the braking system Selecting the brake circuit components 1.

  • Page 140: Placing The Brake Resistors

    2. Select a suitable drive and brake resistor combination for the application according to the rating table on page 139. Take also account of other factors in the drive selection. The braking power must be greater than or equal to the maximum power generated by the motor during braking: >...

  • Page 141: Protecting The System In Fault Situations

    (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. Thermal switch Digital input of the JCU Control Unit.

  • Page 142: Maximum Cable Length

    The maximum length of the resistor cable(s) is 10 m (33 ft). EMC compliance of the complete installation Note: ABB has not verified that the EMC requirements are fulfilled with external user-defined brake resistors and cabling. The EMC compliance of the complete installation must be considered by the customer.

  • Page 143: Technical Data

    400 seconds does not exceed E See page 135. Drive type Frame Brake resistors size Type Rcont (ohm) (kJ) (kW) 380…500 V ACS850-04-710A-5 4 × SAFUR125F500 1.00 14400 ACS850-04-807A-5 4 × SAFUR125F500 1.00 14400 ACS850-04-875A-5 4 × SAFUR125F500 1.00 14400 3AXD00000600931 Resistance value for the resistor assembly.

  • Page 144: Dimensions And Weights

    Dimensions and weights Brake resistor Weight type (kg) SAFUR125F500 SAFUR200F500 SAFUR210F575 ght: FUR180F460: 32 kg FUR125F500: 25 kg FUR200F500: 30 kg FUR210F575: 27 kg 5 5 Ø 7 Resistor braking Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 145: Du/Dt Filters

    FOCH0610-70 ACS850-807A-5 ACS850-875A-5 3AXD00000600931 * Contact ABB for the filter type. Description, installation and technical data of the FOCH filters See FOCH du/dt Filters Hardware Manual (3AFE68577519 [English]). du/dt filters Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...
  • Page 146 du/dt filters Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com...

  • Page 147: Further Information

    Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to ABB website and selecting Sales, Support and Service network.

This manual is also suitable for:

Acs850

Table of Contents