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ABB ACQ810-04 Hardware Manual

Manual is about: drive modules (200 to 500 kW, 300 to 700 hp)

Summary of ACQ810-04

  • Page 1

    Abb industry-specific drives hardware manual acq810-04 drive modules (200 to 500 kw, 300 to 700 hp).

  • Page 2

    List of related manuals you can find manuals and other product documents in pdf format on the internet. See section document library on the internet on the inside of the back cover. For manuals not available in the document library, contact your local abb representative. Drive hardware manuals and g...

  • Page 3: Hardware Manual

    Hardware manual acq810-04 drive modules (200 to 500 kw, 300 to 700 hp) 3aua0000120538 rev a en effective: 2012-06-27 2012 abb oy. All rights reserved. 1. Safety instructions 6. Installation table of contents 8. Start-up.

  • Page 5: Table of Contents

    5 table of contents 1. Safety instructions what this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 use of warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 safe...

  • Page 6

    6 required free space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 free space at top with air inlet gratings in the cabinet door . . . . . . . . . . . . . . . . . . . 40 free space around the drive module . . . . . . . . . . . . . . . . . ....

  • Page 7

    7 implementing a bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 example bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 switching the motor power supply from drive to direct-on-line ....

  • Page 8

    8 safe torque off (xsto) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 control cable connection procedure of units with internal control unit (option +p905) . 99 connecting a pc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 9

    9 control unit (jcu-21) connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 degree of protection . . . . . . . . . . . . . ...

  • Page 10

    10

  • Page 11: Safety Instructions

    Safety instructions 11 1 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...

  • Page 12: Safety In Installation and

    12 safety instructions 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 ...

  • Page 13: •

    Safety instructions 13 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 ...

  • Page 14: General Safety

    14 safety instructions 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 ...

  • Page 15: •

    Safety instructions 15 • - 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. Use safety shoes with met...

  • Page 16: Safe Start-Up and Operation

    16 safety instructions fiber optic cables printed circuit boards safe start-up and operation general safety these warnings are intended for all who plan the operation of the drive or operate the drive. Warning! Ignoring the following instructions can cause equipment malfunction and damage to the fib...

  • Page 17: Introduction to The Manual

    Introduction to the manual 17 2 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 ...

  • Page 18: Flowchart

    18 introduction to the manual operation principle and hardware description describes the drive module. Planning the cabinet installation guides in planning drive cabinets and installing the drive module into a user-defined cabinet. The chapter gives cabinet layout examples and free space requirement...

  • Page 19

    Introduction to the manual 19 unpack and check the units. Check that all necessary optional modules and equipment are present and correct. Only intact units may be started up. Moving and unpacking the unit (page 67 ) checking the delivery (page 70 ) if the drive module has been non-operational for m...

  • Page 20

    20 introduction to the manual connect the external control cables to the drive control unit. Connecting the control cables (page 86 ) control cable connection procedure of units with internal control unit (option +p905) , page 99 check the installation. Installation checklist (page 101 ) commission ...

  • Page 21: Terms and Abbreviations

    Introduction to the manual 21 terms and abbreviations term/abbreviation explanation aibp input bridge protection board apow power supply board bfps power supply board dtc direct torque control emc electromagnetic compatibility emi electromagnetic interference fdna-01 optional devicenet™ fieldbus ada...

  • Page 22

    22 introduction to the manual.

  • Page 23: Operation Principle and

    Operation principle and hardware description 23 3 operation principle and hardware description what this chapter contains this chapter describes the operating principle and construction of the drive module. Product overview the acq810-04 is a drive module for controlling asynchronous ac induction mo...

  • Page 24: Layout

    24 operation principle and hardware description layout the components of the standard unit are shown below. Item description 1 lifting lugs 2 fastening bracket 3 circuit board compartment 4 power supply and fiber optic cables to be connected to the external control unit 5 pe terminal 6 control cable...

  • Page 25

    Operation principle and hardware description 25 the drive module and optional selections are shown below. Item description a drive module 1 input power cabling panel fastened to the drive module 2 output power cabling panel fastened to the drive module 3 front cover. With option +p905, the control p...

  • Page 26: Control Unit Variants

    26 operation principle and hardware description control unit variants the control unit layout is shown below (cover assembly and protective coverings of the slots removed). Control unit without control panel and panel holder (+0j400) a) when covers are removed control unit with control panel (standa...

  • Page 27

    Operation principle and hardware description 27 power connections and control interfaces the diagram shows the power connections and control interfaces of the drive module. Slot 1 slot 2 control unit (jcu) fxx fxxx control panel or pc memory unit 1) power unit 3-phase power supply ac motor u1 v1 w1 ...

  • Page 28

    28 operation principle and hardware description 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 88 ) and connecting a pc (page 99 ) fo...

  • Page 29: Type Designation Label

    Operation principle and hardware description 29 type designation label the type designation label includes an iec and nema rating, ce, c-ul us, and csa markings, a type designation and a serial number, which allow individual recognition of each unit. The type designation label is located on the fron...

  • Page 30

    30 operation principle and hardware description option codes (plus codes) cabling panels h381 power cabling panels (u1, v1, w1, u2, v2, w2 terminals) pedestal 0h354 no pedestal control panel and control unit 0j400 no control panel or panel holder j410 control panel with door mounting kit. Includes c...

  • Page 31: What This Chapter Contains

    Planning the cabinet installation 31 4 planning the cabinet installation what this chapter contains this chapter guides in planning drive cabinets and installing the drive module into a user- defined cabinet so that the front of the module faces the cabinet door. The chapter gives cabinet layout exa...

  • Page 32

    32 planning the cabinet installation planning the layout of the cabinet design a spacious layout to ensure easy installation and maintenance. Sufficient cooling air flow, obligatory clearances, cables and cable support structures all require space. Place the control board(s) away from: • main circui...

  • Page 33

    Planning the cabinet installation 33 layout examples, door open layout examples for units in ip22 and ip54 cabinets are shown below. Optional cabling panels (+h381) are not used. Note 1 : the power cable shields can also be grounded to the drive module grounding terminals. Note 2: see also section r...

  • Page 34: Joints

    34 planning the cabinet installation arranging the grounding inside the cabinet arrange the grounding of the drive module by leaving the contact surfaces of the fastening points unpainted (bare metal-to-metal contact). The module frame will be grounded to the pe busbar of the cabinet via the fasteni...

  • Page 35: Cabinet

    Planning the cabinet installation 35 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 t...

  • Page 36

    36 planning the cabinet installation grounding is made with short flat copper braids for low inductance. One-point high- frequency grounding cannot be used due to the long distances inside the cabinet. • 360° high frequency grounding of the cable shields at the cable lead-throughs improves the emc s...

  • Page 37: Lead-Through

    Planning the cabinet installation 37 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. Example cable lead-through 1 to power cable terminals 2 cable shield 3 pe (groun...

  • Page 38: Planning The Cooling

    38 planning the cabinet installation planning the cooling note following guidelines when planning the cooling of the cabinet: • ventilate the installation site sufficiently so that the cooling air flow and ambient temperature requirements of the drive module are met, see pages 121 and 124 . The inte...

  • Page 39

    Planning the cabinet installation 39 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...

  • Page 40: Required Free Space

    40 planning the cabinet installation required free space free space around the drive module is needed for ensuring that sufficient cooling air flows through the module and the module cools properly. Free space at top with air inlet gratings in the cabinet door the required free space at the top of t...

  • Page 41

    Planning the cabinet installation 41 planning the placement of the control panel note the following alternatives when planning the placement of the control panel: • the control panel can be snapped on the control unit of the drive. See page 26 . • the control panel can be mounted onto the cabinet do...

  • Page 42

    42 planning the cabinet installation.

  • Page 43: Planning The Electrical

    Planning the electrical installation 43 5 planning the electrical installation what this chapter contains this chapter contains the instructions that you must follow when selecting the motor, cables, protections, cable routing and way of operation for the drive system. Note: the installation must al...

  • Page 44

    44 planning the electrical installation other regions the disconnecting device must conform to the applicable safety regulations. Selecting and dimensioning the main contactor if a main contactor is used, its utilization category (number of operations under load) must be ac-1 according to iec 60947-...

  • Page 45

    Planning the electrical installation 45 requirements table the following table shows how to select the motor insulation system and when optional abb d u /d t filters, insulated n-end (non-drive end) motor bearings and abb common mode filters are required. Failure of the motor to fulfil the following...

  • Page 46

    46 planning the electrical installation *manufactured before 1.1.1998 **for motors manufactured before 1.1.1998, check for additional instructions with the motor manufacturer. ***if the intermediate dc circuit voltage of the drive is increased from the nominal level by resistor braking, check with t...

  • Page 47

    Planning the electrical installation 47 additional requirements for high-output motors and ip23 motors if you will use a motor with the rated output power higher than what is stated for the particular frame size in en 50347 (2001), or if the degree of protection is ip23, follow these guidelines when...

  • Page 48

    48 planning the electrical installation hxr and ama motors all ama machines (manufactured in helsinki) for drive systems have form-wound windings. All hxr machines manufactured in helsinki starting 1.1.1998 have form-wound windings. Abb motors of types other than m2_, m3_, m4_, hx_ and am_ use the s...

  • Page 49: Selecting The Power Cables

    Planning the electrical installation 49 selecting the power cables general rules dimension the input power and motor cables according to local regulations : • dimension the cable to carry the drive load current. See chapter technical data for the rated currents. • select a cable rated for at least 7...

  • Page 50

    50 planning the electrical installation typical power cable sizes the table below gives copper and aluminium cable types with concentric copper shield for the drives with nominal current. See also terminal and lead-through data for the power cables on page 121. 1) the cable sizing is based on max. 9...

  • Page 51

    Planning the electrical installation 51 alternative power cable types the power cable types that can be used with the drive are represented below. Motor cable shield if the motor cable shield is used as the sole protective earth conductor of the motor, ensure that the conductivity of the shield is s...

  • Page 52: Selecting The Control Cables

    52 planning the electrical installation additional us requirements use type mc continuous corrugated aluminum armor cable with symmetrical grounds or shielded power cable 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 a...

  • Page 53

    Planning the electrical installation 53 signals allowed to be run in the same cable relay-controlled signals, providing their voltage does not exceed 48 v, can be run in the same cables as digital input signals. It is recommended that the relay-controlled signals be run as twisted pairs. Relay cable...

  • Page 54

    54 planning the electrical installation separate control cable ducts continuous motor cable shield or enlosure for equipment in the motor cable to ensure safety and minimize the emission level when safety switches, contactors, connection boxes or similar equipment are installed in the motor cable be...

  • Page 55: Protection

    Planning the electrical installation 55 implementing thermal overload and short-circuit protection protecting the drive and input power cable in short-circuits protect the drive with fuses (1) and the input cable with fuses (2) or a circuit breaker (3) as shown below: size the fuses or circuit break...

  • Page 56

    56 planning the electrical installation protecting the motor against thermal overload according to regulations, the motor must be protected against thermal overload and the current must be switched off when overload is detected. The drive includes a motor thermal protection function that protects th...

  • Page 57

    Planning the electrical installation 57 implementing the safe torque off (sto) function the drive supports the safe torque off function according to standards en 61800-5-2:2007; en 954-1:1997; iec/en 60204-1:1997; en 61508:2002 and en 1037:1996. The safe torque off function disables the control volt...

  • Page 58: Drive

    58 planning the electrical installation implementing the power loss ride-through function implement the power loss ride-through function as follows: 1. Activate the power loss ride-through function of the drive (parameter 47.02 undervolt ctrl in the standard pump control program). 2. If the installa...

  • Page 59

    Planning the electrical installation 59 using a contactor between the drive and the motor arrange the control of the output contactor by applying one of the alternatives described below. Alternative 1: when you have selected to use the default motor control mode (dtc) and motor coast stop in the dri...

  • Page 60

    60 planning the electrical installation implementing a bypass connection if bypassing is required, employ mechanically or electrically interlocked contactors between the motor and the drive and between the motor and the power line. Ensure with interlocking that the contactors cannot be closed simult...

  • Page 61

    Planning the electrical installation 61 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...

  • Page 62: Example Circuit Diagram

    62 planning the electrical installation 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...

  • Page 63: Installation

    Installation 63 6 installation what this chapter contains in this chapter, the drive module is installed in a 400 mm wide rittal ts 8 cabinet in a bookshelf way of mounting: the module is placed in an upright position on the cabinet bottom with its front facing the cabinet door. The following rittal...

  • Page 64

    64 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 cabinet...

  • Page 65

    Installation 65 note 4: mounting the drive module to an assembly pane l mount the assembly support as shown below. M4×12 torx.

  • Page 66

    66 installation note 5: mounting the rubber grommet of units with optional cabling panels (+h381) installing the input power cables through the rubber grommet of optional cabling panels provides the degree of protection of ip20 for the unit. Mount the grommet (if used) as follows: 1. Cut adequate ho...

  • Page 67: Safety

    Installation 67 safety warning! Only qualified electricians are allowed to carry out the electrical installation 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. Checking the installation sit...

  • Page 68

    68 installation description of the package contents 1 input cabling panel (option +h381), see contents below. 2 output cabling panel (option +h381), see contents below. 3 plywood support 4 drive module with factory installed options and multilingual residual voltage warning sticker, top guide plate,...

  • Page 69

    Installation 69 1 2 3 4 5 6 7 8 2 1 3 4 5 6 7 8 ramp package contents 1 screw package 2 fastening bracket 3 telescopic extraction and insertion ramp 4 pe terminal 5 cardboard box 6 pedestal guide plate 7 top guide plate 8 support 5 6 7 8 9 sub - 3a - 3a 1 8 2 3 4 5 6 7 9 7 1 2 3 4 5 6 8 output power...

  • Page 70: Checking The Delivery

    70 installation checking the delivery check that all items listed under section moving and unpacking the unit are present. 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 i...

  • Page 71

    Installation 71 motor and motor cable check the insulation of the motor and motor cable as follows: 1. Check that the motor cable is disconnected from the drive output terminals u2, v2 and w2. 2. Measure the insulation resistance between each phase conductor and the protective earth conductor using ...

  • Page 72

    72 installation overall flowchart of the installation process this flowchart describes the installation process of the units listed under what this chapter contains on page 63 . Installing the mechanical accessories into the cabinet for frame g1, see the assembly drawing on page 75 . For frame g2, s...

  • Page 73

    Installation 73 note: if the thickness of the bottom plate is not 2.5 mm (0.1 in.), adjust the dimensions accordingly. 4. Install the output cabling panel. 5. Install the side guides to the output cabling panel (2 screws for each side guide). 6. Mount the grounding busbar to the input cabling panel ...

  • Page 74

    74 installation 7. Mount the side guides to the input cabling panel (2 screws for each side guide) and mount the input cabling panel to the punched section..

  • Page 75: Assembly Drawing (Frame G1)

    Installation 75 assembly drawing (frame g1).

  • Page 76: Assembly Drawing (Frame G2)

    76 installation assembly drawing (frame g2).

  • Page 77: Connecting The Power Cables

    Installation 77 connecting the power cables warning! Follow the safety instructions, page 11 . Ignoring the instructions can cause physical injury or death, or damage to the equipment connection diagram input output u1 v1 w1 u2 v2 w2 acq810-04- ...+h381 u1 v1 w1 3 ~ motor udc+ udc - u2 v2 w2 u1 v1 w...

  • Page 78

    78 installation power cable connection procedure warning! Follow the instructions in chapter safety instructions . Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Lead the input cables into the inside of the cabinet. Ground the cable shield 360° at the le...

  • Page 79

    Installation 79 note: the input and output power cables must fit inside the area marked with diagonal lines in the image below to avoid chafing of the cables when the drive module is inserted into the cabinet. C a view without cabinet side plate in place. A) 360-degree grounding at the lead-through ...

  • Page 80

    80 installation ground the motor cable shield at the motor end as follows: • 360 degrees at the lead-through of the motor terminal box (1) • or by twisting the shield as follows: flattened width > 1/5 · length. Mounting the drive module into the cabinet warning! Follow the safety instructions, page ...

  • Page 81

    Installation 81 mounting procedure 1. Mount the fastening bracket to the drive module. 2. Mount the grounding busbar that has been previously mounted to the input cabling panel to the drive module. 3. Install the extraction and insertion ramp to the cabinet base with two screws. 4. Remove the upper ...

  • Page 82

    82 installation 6. Connect the busbars of the drive module to the busbars of the cabling panels. Combi screw m12, 70 n·m (52 lbf·ft). 7. Mount the drive module to the cabinet from top and bottom as shown below and in the assembly drawing on page 84 (frame g1) or page 85 (frame g2) . Note : the screw...

  • Page 83

    Installation 83 3 6a 6b 5 4 8 4 8 6a 6b 7a 7b 7b.

  • Page 84

    84 installation assembly drawing of installing the drive module to the cabinet (frame g1).

  • Page 85

    Installation 85 assembly drawing of installing the drive module to the cabinet (frame g2).

  • Page 86

    86 installation 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...

  • Page 87

    Installation 87 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. Pres...

  • Page 88

    88 installation 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. Connecting the external control unit to the drive module warning! Handle the fiber optic cables with care. When unplugging optic...

  • Page 89

    Installation 89 3aua0000038989 txd = transmitter rxd = receiver jrib v2 v1 v7 v6 1 2 apow 2 jint 3 jrib 1 4 4 jgdr.

  • Page 90

    90 installation 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. Lift the unit onto the screws and ti...

  • Page 91: Installing Optional Modules

    Installation 91 mounting the control unit horizontally on a din rail 1. Fasten the latches (a) to the back of the control unit with three screws. 2. Click the control unit to the rail as shown below (b). Installing optional modules mechanical installation optional modules such as a fieldbus adapters...

  • Page 92

    92 installation note: correct installation of the screw is essential for fulfilling the emc requirements and for proper operation of the module. Wiring the modules see the appropriate optional module manual for specific installation and wiring instructions. See page 93 for routing the cables..

  • Page 93

    Installation 93 connecting the control cables to the terminals of the control unit 1. Route the cables to the control unit as shown below. 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. Only ...

  • Page 94

    94 installation 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 jumpers, page 96. Use shrink tubing or insulating tape to contain a...

  • Page 95

    Installation 95 default i/o connection diagram xpow external power input 24 v dc, 1.6 a +24vi 1 gnd 2 xro1, xro2 relay output ro1 [ready] 250 v ac / 30 v dc 2 a no 1 com 2 nc 3 relay output ro2 [fault(-1)] 250 v ac / 30 v dc 2 a no 4 com 5 nc 6 xd24 +24 v dc* +24vd 1 digital input ground dignd 2 +24...

  • Page 96

    96 installation jumpers di/dio grounding selector (located between xd24 and xdi) – determines whether the dignd (ground for digital inputs di1…di4) floats, or if it is connected to diognd (ground for di5, dio1 and dio2). See the jcu isolation and grounding diagram on page 124 . If dignd floats, the ...

  • Page 97

    Installation 97 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 supp...

  • Page 98

    98 installation 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, • the i/o board terminals ...

  • Page 99: Control Unit (Option +P905)

    Installation 99 control cable connection procedure of units with internal control unit (option +p905) 1. Fasten the clamp plate to the control unit with two screws from front, see fastening the control cable clamp plate on page 88 . 2. Fasten the optional modules if not fastened already. 3. Lead the...

  • Page 100

    100 installation.

  • Page 101: Installation Checklist

    Installation checklist 101 7 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 instruction...

  • Page 102

    102 installation checklist drive option modules and other components type and number of option modules and other equipment is correct. Option modules and other equipment are not damaged. Option modules and terminals are labelled correctly. The placement of option modules and other equipment inside t...

  • Page 103

    Installation checklist 103 the cooling air will flow freely in and out of the drive cabinet, and air recirculation inside the cabinet will not be possible (air baffle plates are on place). If the drive has been stored over one year: the electrolytic dc capacitors in the dc link of the drive have bee...

  • Page 104

    104 installation checklist.

  • Page 105: Start-Up

    Start-up 105 8 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 installation checklist, and that the motor and dr...

  • Page 106

    106 start-up.

  • Page 107: Fault Tracing

    Fault tracing 107 9 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. Warning and fault messages see the firmware manual for the descriptions, causes and remedies of the control program wa...

  • Page 108

    108 fault tracing.

  • Page 109: Maintenance

    Maintenance 109 10 maintenance what this chapter contains this chapter contains preventive maintenance instructions of the drive module. Applicability the drive module replacement described in this chapter applies to the rittal ts 8 example installation of chapter installation . The other maintenanc...

  • Page 110: Cabinet

    110 maintenance consult your local abb service representative for more details on the maintenance. On the internet, go to http://www.Abb.Com/drivesservices . Cabinet cleaning the interior of the cabinet warning! Follow the safety instructions, page 11 . Ignoring the instructions can cause physical i...

  • Page 111: Heatsink

    Maintenance 111 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 11 . Ignoring the instructions can cause phys...

  • Page 112: Fans

    112 maintenance fans the actual lifespan depends on the running time of the fan, ambient temperature and dust concentration. See the firmware manual for the actual signal which indicates the running time of the cooling fan. For resetting the running time signal after a fan replacement, please contac...

  • Page 113

    Maintenance 113 replacing the main cooling fans warning! Follow the safety instructions, page 11 . 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 drive module on page 114 . ...

  • Page 114: Replacing The Drive Module

    114 maintenance replacing the drive module warning! Follow the safety instructions, page 11 . 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 duri...

  • Page 115

    Maintenance 115 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. 6 3 4 8 5 5 2 2.

  • Page 116: Capacitors

    116 maintenance capacitors the drive intermediate circuit employs several electrolytic capacitors. Their lifespan depends on the operating time of the drive, loading and ambient temperature. The lifespan of the capacitor can be prolonged by lowering the ambient temperature. It is not possible to pre...

  • Page 117: Technical Data

    Technical data 117 11 technical data what this chapter contains this chapter contains the technical specifications of the drive, for example, the ratings, sizes and technical requirements, provisions for fulfilling the requirements for ce and other markings. Ratings the ratings of the drive modules ...

  • Page 118

    118 technical data derating the continuous output currents stated above must be derated if any of the following conditions apply: • • ambient temperature exceeds +40 °c (+104°f) • drive is installed higher than 1000 m (3280 ft) above sea level. Note: the final derating factor is a multiplication of ...

  • Page 119: Fuses (Iec)

    Technical data 119 fuses (iec) ultrarapid (ar) fuses drive type acq810- 04… input current a fuse a a 2 s v manufacturer type din 43620 size -377a-4 380 630 490000 690 bussmann 170m6810d din2 -480a-4 490 800 490000 690 bussmann 170m6812d din3 -570a-4 570 1000 985000 690 bussmann 170m6814d din3 -634a-...

  • Page 120

    120 technical data dimensions, weights and free space requirements for requirements of free space around the drive module, see page 40 . Drive type acq810-04 h1 h2 w1 w2 d1 d2 weight 1 mm mm mm mm mm mm kg -377a-4 1462 1560 305 329 505 515 161 -480a-4 1462 1560 305 329 505 515 161 -570a-4 1462 1560 ...

  • Page 121

    Technical data 121 losses, cooling data and noise terminal and lead-through data for the power cables the maximum accepted cable size is 4 × (3 × 240) mm 2 or 4 × (3 × 500 awg). Screw size for connecting busbars to the drive module input and output busbars: m12, tightening torque 50...75 n·m. Units ...

  • Page 122: Motor Connection Data

    122 technical data electrical power network specification voltage ( u 1 ) 380...500 vac 3-phase ± 10% rated conditional short- circuit current (iec 60439-1) 65 ka when protected by fuses given in the fuse tables frequency 48 to 63 hz, maximum rate of change 17%/s imbalance max. ± 3% of nominal phase...

  • Page 123

    Technical data 123 digital inputs/outputs dio1 and dio2 (xdio:1 and xdio:2) input/output mode selection by parameters. Dio1 can be configured as a frequency input (0…16 khz) for 24 v level square wave signal (sinusoidal or other wave form cannot be used). Dio2 can be configured as a 24 v level squar...

  • Page 124: Efficiency

    124 technical data isolation and grounding diagram 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). Note: the degree of protection of ip20 requires that the input po...

  • Page 125: Materials

    Technical data 125 air temperature -15 to +55 °c (5 to 131 °f). No frost allowed. See section derating . -40 to +70 °c (-40 to +158 °f) -40 to +70 °c (-40 to +158 °f) relative humidity 5 to 95% max. 95% max. 95% no condensation allowed. Maximum allowed relative humidity is 60% in the presence of cor...

  • Page 126: Ce Marking

    126 technical data 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 2006/95/ec and directive 2004/108/ec). Compliance with the european low voltage directive the compliance with the european low vol...

  • Page 127

    Technical data 127 category c3 the drive complies with the standard with the following provisions: 1. The motor and control cables are selected as specified in the hardware manual . 2. The drive is installed according to the instructions given in the hardware manual . 3. Maximum cable length is 100 ...

  • Page 128

    128 technical data.

  • Page 129: Dimension Drawings

    Dimension drawings 129 12 dimension drawings what this chapter contains this chapter contains dimension drawings of the drive modules with optional parts for rittal ts 8 cabinet assembly..

  • Page 130

    130 dimension drawings frame g1 – drive module dimensions.

  • Page 131: Cabling Panels (+H381)

    Dimension drawings 131 frame g1 – drive module dimensions with optional cabling panels (+h381).

  • Page 132

    132 dimension drawings.

  • Page 133: Ts 8 Cabinet

    Dimension drawings 133 frame g1 – cabling panels (+h381) installed into a rittal ts 8 cabinet.

  • Page 134

    134 dimension drawings frame g2 – drive module dimensions.

  • Page 135: Cabling Panels (+H381)

    Dimension drawings 135 frame g2 – drive module dimensions with optional cabling panels (+h381).

  • Page 136

    136 dimension drawings.

  • Page 137: Ts 8 Cabinet

    Dimension drawings 137 frame g2 – cabling panels (+h381) installed into a rittal ts 8 cabinet.

  • Page 138: Bottom Plate

    138 dimension drawings bottom plate.

  • Page 139: Example Circuit Diagrams

    Example circuit diagrams 139 13 example circuit diagrams what this chapter contains this chapter shows an example circuit diagram for a cabinet-installed drive module..

  • Page 140: Example Circuit Diagram

    140 example circuit diagrams 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). **motor temperatur...

  • Page 141: Filters

    Du/dt filters 141 14 d u /d t filters what this chapter contains this chapter describes how to select d u /d t filters for the drive. D u /d t filters when is d u /d t filter needed? See section checking the compatibility of the motor and drive , page 44 . Selection table d u /d t filter types for t...

  • Page 142

    142 du/dt filters.

  • Page 143

    Further information product and service inquiries 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 www.Abb.Com/drives an...

  • Page 144

    3 a u a 0 000 120 538 rev a (en) 20 12-06 -27 contact us www.Abb.Com/drives www.Abb.Com/drivespartners.