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ABB ACS800-04 Hardware Manual - What This Chapter Contains

Other manuals for ACS800-04: Hardware Manual
Manual is about: Drive Modules

Summary of ACS800-04

  • Page 1

    Acs800 hardware manual acs800-04 and acs800-04m drive modules (45 to 560 kw) acs800-u4 drive modules (60 to 600 hp).

  • Page 2

    Acs800 single drive manuals hardware manuals (appropriate manual is included in the delivery) acs800-01/u1 hardware manual 0.55 to 160 kw (0.75 to 200 hp) 3afe64382101 (english) acs800-01/u1/04 marine supplement 0.55 to 160 kw (0.75 to 200 hp) 3afe64291275 (english) acs800-11/u11 hardware manual 5.5...

  • Page 3: Hardware Manual

    Acs800-04 and acs800-04m drive modules 45 to 560 kw acs800-u4 drive modules 60 to 600 hp hardware manual 3afe64671006 rev f en effective: 15.6.2007 © 2007 abb oy. All rights reserved..

  • Page 5: Safety Instructions

    Safety instructions 5 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. R...

  • Page 6: •

    Safety instructions 6 installation andmaintenance work 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 an...

  • Page 7: •

    Safety instructions 7 grounding these instructions are intended for all who are responsible for the grounding of the drive. • at installation sites above 2000 m (6562 ft), the terminals of the rmio board and optional modules attached to the board do not fulfil the protective extra low voltage (pelv)...

  • Page 8: •

    Safety instructions 8 mechanical installation and maintenance 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: • handle the unit carefully. • acs800-01, acs800-11, a...

  • Page 9: •

    Safety instructions 9 printed circuit boards fibre optic cables 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 ...

  • Page 10: Operation

    Safety instructions 10 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 s...

  • Page 11: Permanent Magnet Motor

    Safety instructions 11 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 magne...

  • Page 12

    Safety instructions 12.

  • Page 13: Table of Contents

    Table of contents 13 table of contents acs800 single drive manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 safety instructions what this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 14

    Table of contents 14 control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 connections of the drive control unit (rdcu) in frame sizes r7 and r8 . . . . . . . . . . . . . . .29 operation . . . . . . . . . . ...

  • Page 15

    Table of contents 15 selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 general rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 ...

  • Page 16

    Table of contents 16 motor control and i/o board (rmio) what this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 to which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 17

    Table of contents 17 technical data what this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 iec data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 18

    Table of contents 18 “c-tick” marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 19: About This Manual

    About this manual 19 about this manual what this chapter contains this chapter describes the intended audience and contents of the manual. It contains a flowchart of steps in checking the delivery, installing and commissioning the drive. The flowchart refers to chapters/sections in this manual and o...

  • Page 20: Contents

    About this manual 20 contents the chapters of this manual are briefly described below. Safety instructions give safety instructions for the installation, commissioning, operation and maintenance of the drive. About this manual introduces this manual. The acs800-04/u4 and acs800-04m describes the dri...

  • Page 21: Product Training

    About this manual 21 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 and sele...

  • Page 22

    About this manual 22 providing feedback on abb drives manuals your comments on our manuals are welcome. Go to www.Abb.Com/drives , then select successively drives – document library – manuals feedback form on the right pane..

  • Page 23: What This Chapter Contains

    The acs800-04/u4 and acs800-04m 23 the acs800-04/u4 and acs800-04m what this chapter contains this chapter describes the construction and operating principle of the drive in short. The acs800-04/u4 the acs800-04/u4 is an ip 00 drive module for controlling ac motors. It is to be installed into a cabi...

  • Page 24: The Acs800-04M

    The acs800-04/u4 and acs800-04m 24 the acs800-04m the acs800-04m is delivered as non-pre-assembled kits, which provide more alternatives in assembling the units than the basic acs800-04. Example configurations motor and brake busbars on the right-hand long side of the module and dc busbars on the le...

  • Page 25: Type Designation Label

    The acs800-04/u4 and acs800-04m 25 type designation label the type designation label includes an iec and nema rating, c-ul us, and csa markings, a type code and a serial number, which allow individual recognition of each unit. The first digit of the serial number refers to the manufacturing plant. T...

  • Page 26: Type Code

    The acs800-04/u4 and acs800-04m 26 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. Acs800-04- 0170-5). The optional selections are given thereafter, separated by plus signs (e.G. +e202...

  • Page 27

    The acs800-04/u4 and acs800-04m 27 type code for acs800-04m non-pre-assembled units (delivered as kits) selection alternatives product series acs800 product series type 04m drive module. When no options are selected: 6-pulse diode input bridge, ip 00, top entry, rdcu drive control unit, standard con...

  • Page 28: Control Interfaces

    The acs800-04/u4 and acs800-04m 28 control interfaces this diagram shows the control interfaces and the main circuit of the drive. ~ = ~ = motor control and i/o board (rmio) external control via analogue/digital inputs and outputs input power output power r- udc+ udc- r+ optional module 1: rmba, rai...

  • Page 29

    The acs800-04/u4 and acs800-04m 29 connections of the drive control unit (rdcu) in frame sizes r7 and r8 operation this table describes the operation of the main circuit in short. Component description six-pulse rectifier converts the three-phase ac voltage to dc voltage capacitor bank energy storag...

  • Page 30

    The acs800-04/u4 and acs800-04m 30 printed circuit boards the drive contains the following printed circuit boards as standard: • main circuit board (aint) • motor control and i/o board (rmio) with a fibre optic link to the aint board • input bridge control board (ainp) • input bridge protection boar...

  • Page 31: Mechanical Installation

    Mechanical installation 31 mechanical installation what this chapter contains this chapter describes the mechanical installation of the drive cabinet generally. Follow the specific instructions given by the panel builder. For the mechanical assembly and dimensional drawings of the drive module, refe...

  • Page 32: Electric Welding

    Mechanical installation 32 cable channel in the floor below the cabinet when a cable channel is constructed below the cabinet, ensure that cabinet weight lies on the sections which the floor carries. Fastening the cabinet to the floor and wall fasten the cabinet to the floor and wall/roof according ...

  • Page 33: What This Chapter Contains

    Planning the electrical installation 33 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 alwa...

  • Page 34

    Planning the electrical installation 34 3. Check that the motor voltage rating meets the application requirements: see notes 6 and 7 below the requirements table , page 38. 4. Consult the motor manufacturer before using a motor in a drive system where the motor nominal voltage differs from the ac po...

  • Page 35

    Planning the electrical installation 35 protecting the motor insulation and bearings the output of the drive comprises – regardless of output frequency – pulses of approximately 1.35 times the equivalent mains network voltage with a very short rise time. This is the case with all drives employing mo...

  • Page 36

    Planning the electrical installation 36 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 r...

  • Page 37

    Planning the electrical installation 37 * 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 or by the ...

  • Page 38

    Planning the electrical installation 38 note 2: explosion-safe (ex) motors the motor manufacturer should be consulted regarding the construction of the motor insulation and additional requirements for explosion-safe (ex) motors. Note 3: high-output motors and ip 23 motors for motors with higher rate...

  • Page 39

    Planning the electrical installation 39 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 ...

  • Page 40: Supply Connection

    Planning the electrical installation 40 supply connection disconnecting device (disconnecting means) acs800-01, acs800-u1, acs800-11, acs800-u11, acs800-31, acs800-u31, acs800-02 and acs800-u2 without enclosure extension, acs800-04, acs800-u4 install a hand-operated input disconnecting device (disco...

  • Page 41

    Planning the electrical installation 41 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 cur...

  • Page 42

    Planning the electrical installation 42 protection against short-circuit inside the drive or in the supply cable arrange the protection according to the following guide lines. 1) size the fuses according to instructions given in chapter technical data. The fuses will protect the input cable in short...

  • Page 43: Ground Fault Protection

    Planning the electrical installation 43 2) circuit breakers which have been tested by 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. The protective characteristi...

  • Page 44

    Planning the electrical installation 44 power-loss ride-through function the power-loss ride-through function is activated when parameter 20.06 undervoltage ctrl is set to on (default in standard control program). Acs800-07/u7 units without line contactor the power-loss ride-through funtion is not i...

  • Page 45

    Planning the electrical installation 45 prevention of unexpected start the acs800-01/u1, acs800-04/u4, acs800-11/u11, acs800-31/u31 and acs800-07/u7 can be equipped with an optional prevention of unexpected start function according to standards iec/en 60204-1: 1997; iso/dis 14118: 2000 and en 1037: ...

  • Page 46: Selecting The Power Cables

    Planning the electrical installation 46 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 f...

  • Page 47

    Planning the electrical installation 47 alternative power cable types power cable types that can be used with the drive are represented below. Motor cable shield to effectively suppress radiated and conducted radio-frequency emissions, the shield conductivity must be at least 1/10 of the phase condu...

  • Page 48

    Planning the electrical installation 48 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 t...

  • Page 49

    Planning the electrical installation 49 if there are power factor compensation capacitors in parallel with the three phase input of the drive: 1. Do not connect a high-power capacitor to the power line while the drive is connected. The connection will cause voltage transients that may trip or even d...

  • Page 50: Of Inductive Loads

    Planning the electrical installation 50 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) agai...

  • Page 51

    Planning the electrical installation 51 selecting the control cables all control cables must be shielded. Use a double-shielded twisted pair cable (figure a, e.G. Jamak by nk cables, finland) for analogue signals. This type of cable is recommended for the pulse encoder signals also. Employ one indiv...

  • Page 52: Routing The Cables

    Planning the electrical installation 52 connection of a motor temperature sensor to the drive i/o warning! Iec 60664 requires double or reinforced insulation between live parts and the surface of accessible parts of electrical equipment which are either non- conductive or conductive but not connecte...

  • Page 53

    Planning the electrical installation 53 a diagram of the cable routing is shown below. Control cable ducts 90 ° min 500 mm (20 in.) motor cable input power cable control cables min 200 mm (8 in.) min 300 mm (12 in.) motor cable power cable drive 24 v 24 v 230 v lead 24 v and 230 v (120 v) control ca...

  • Page 54

    Planning the electrical installation 54.

  • Page 55: Electrical Installation

    Electrical installation 55 electrical installation what this chapter contains this chapter instructs in the cabling of the drive. Warnings warning! Only qualified electricians are allowed to carry out the work described in this chapter. Follow the safety instructions on the first pages of this manua...

  • Page 56: It (Ungrounded) Systems

    Electrical installation 56 it (ungrounded) systems a drive equipped with no emc filter or with emc filter +e210 is suitable for it (ungrounded systems). If the drive is equipped with emc filter +e202, disconnect the filter before connecting the drive to an ungrounded system. For detailed instruction...

  • Page 57: Example Wiring Diagram

    Electrical installation 57 example wiring diagram the diagram below presents an example for the main wiring. Note that the diagram includes optional components which are not included in a basic delivery (marked *) and equipment not available as plus code options (marked **). ** m o to r te mp eratu ...

  • Page 58

    Electrical installation 58 power cable connection diagram input output u1 v1 w1 1) u2 v2 w2 udc+ r+ udc - r - l1 l2 l3 (pe) (pe) pe 2) drive module pe * for alternatives, see planning the electrical installation : disconnecting device (disconnecting means) * grounding of the motor cable shield at th...

  • Page 59

    Electrical installation 59 grounding of the cable shields emc sleeve * lead-through plate strip this part of the cable * cable shield base plate pe terminal of the cabinet or drive module strain relief to power terminals example cable lead-through grommet emi conductive lead-through side view cushio...

  • Page 60: Fastening Us Cable Lugs

    Electrical installation 60 fastening us cable lugs example mounting us cable lugs can be connected directly to the output busbars or to the terminals as follows. 1 3/4” 1/2” bolt.

  • Page 61: Connections Of The Rdcu

    Electrical installation 61 connections of the rdcu the rdcu drive control unit contains the rmio board where the user’s control cables are connected. Warning! Handle the fibre optic cables with care. When unplugging optic cables, always grab the connector, not the cable itself. Do not touch the ends...

  • Page 62

    Electrical installation 62 connecting the control cables to the rmio board 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) ].Tighten the screws to secure the connectio...

  • Page 63

    Electrical installation 63 settings of the cooling fan transformer the voltage transformer of the cooling fan is located at the top right-hand corner of the drive module. Remove the front cover for adjusting the settings and replace the cover after setting. Installation of optional modules the optio...

  • Page 64: Warning Sticker

    Electrical installation 64 pulse encoder module cabling fibre optic link a ddcs fibre optic link is provided via the rdco optional module for pc tools, master/follower link, ndio, ntac, naio, aima i/o module adapter and fieldbus adapter modules of type nxxx. See rdco user’s manual [3afe64492209 (eng...

  • Page 65: What This Chapter Contains

    Motor control and i/o board (rmio) 65 motor control and i/o board (rmio) what this chapter contains this chapter shows • external control connections to the rmio board for the acs800 standard control program (factory macro) • specifications of the inputs and outputs of the board. To which products t...

  • Page 66

    Motor control and i/o board (rmio) 66 note on external power supply external +24 v power supply for the rmio board is recommended if • the application requires a fast start after connecting the input power supply • fieldbus communication is required when the input power supply is disconnected. The r...

  • Page 67

    Motor control and i/o board (rmio) 67 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 firmwar...

  • Page 68

    Motor control and i/o board (rmio) 68 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 ...

  • Page 69: Rmio Board Specifications

    Motor control and i/o board (rmio) 69 rmio board specifications analogue inputs with standard control program two programmable differential current inputs (0 ma / 4 ma ... 20 ma, r in = 100 ohm) and one programmable differential voltage input (- 10 v / 0 v / 2 v ... +10 v, r in = 200 kohm). The anal...

  • Page 70

    Motor control and i/o board (rmio) 70 relay outputs three programmable relay outputs switching capacity 8 a at 24 vdc or 250 vac, 0.4 a at 120 vdc minimum continuous current 5 ma rms at 24 vdc maximum continuous current 2 a rms insulation test voltage 4 kvac, 1 minute ddcs fibre optic link with opti...

  • Page 71

    Motor control and i/o board (rmio) 71 isolation and grounding diagram x20 1 vref- 2 agnd x21 1 vref+ 2 agnd 3 ai1+ 4 ai1- 5 ai2+ 6 ai2- 7 ai3+ 8 ai3- 9 ao1+ 10 ao1- 11 ao2+ 12 ao2- x22 1 di1 2 di2 3 di3 4 di4 9 dgnd1 5 di5 6 di6 7 +24vd 8 +24vd 11 diil 10 dgnd2 x23 1 +24 v 2 gnd x25 1 ro1 2 ro1 3 ro...

  • Page 72

    Motor control and i/o board (rmio) 72.

  • Page 73: Maintenance

    Maintenance 73 maintenance what this chapter contains this chapter contains preventive maintenance instructions. Safety warning! Read the safety instructions on the first pages of this manual before performing any maintenance on the equipment. Ignoring the safety instructions can cause injury or dea...

  • Page 74: Maintenance Intervals

    Maintenance 74 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 when stored capacitor reforming see reforming . Every 6 to 1...

  • Page 75: Layout

    Maintenance 75 layout the layout stickers of the drive are shown below. The stickers show all possible components. Not all of them are present in each delivery or described here. Components that need to be changed regularly are listed below: designation component y41 cooling fan c_ capacitors code: ...

  • Page 76: Heatsink

    Maintenance 76 heatsink check the cleanliness of the cabinet and the surroundings. When necessary, clean the interior of the cabinet with a soft brush and a vacuum cleaner. The module heatsink fins pick up dust from the cooling air. The drive runs into overtemperature warnings and faults if the heat...

  • Page 77

    Maintenance 77 replacing the fan (r7) 1. Remove the front cover. 2. Disconnect the discharging resistor wire(s). 3. Remove the dc capacitor pack by undoing the red fixing screws and pulling the pack out. 4. Disconnect the fan supply wires (detachable connector). 5. Disconnect the fan capacitor wires...

  • Page 78

    Maintenance 78 replacing the fan (r8) 1. Remove the front cover. 2. Disconnect the fan capacitor and power supply wires. 3. Undo the red fastening screws of the plastic side cover of the fan. Shift the cover to the right to free its right-hand edge and lift the cover off. 4. Undo the red fastening s...

  • Page 79: Capacitors

    Maintenance 79 capacitors the drive intermediate circuit employs several electrolytic capacitors. Their lifespan is at least 90 000 hours depending on the operating time of the drive, loading and ambient temperature. Capacitor life can be prolonged by lowering the ambient temperature. It is not poss...

  • Page 80

    Maintenance 80 replacing the capacitor pack (r8) 1. Remove the front cover. Remove the profiled side plate. 2. Disconnect the discharging resistor wires. 3. Undo the fastening screws. 4. Lift the capacitor pack out. 5. Install the new capacitor pack in reverse order to the above. 3 3 2 2 m10 m6 2 pc...

  • Page 81: Replacing The Drive Module

    Maintenance 81 replacing the drive module • disconnect the input power cable from the module. • disconnect the power supply cable and the fibre optic cables from the rmio board and coil them on the top of the converter module. • disconnect the busbars outside the module. • undo the upper fastening s...

  • Page 82: Leds

    Maintenance 82 leds this table describes leds of the drive. Where led when the led is lit rmio board red drive in fault state green the power supply on the board is ok. Control panel mounting platform red drive in fault state green the main + 24 v power supply for the control panel and the rmio boar...

  • Page 83: Technical Data

    Technical data 83 technical data what this chapter contains this chapter contains the technical specifications of the drive, e.G. The ratings, sizes and technical requirements, provisions for fulfilling the requirements for ce and other markings, and warranty policy. Iec data ratings the iec ratings...

  • Page 84

    Technical data 84 1) 50% overload is available for one minute every 5 minutes if ambient temperature is less than 25 °c. If ambient temperature is 40 °c, max. Available overload is 37%. 2) 50% overload is available for one minute every 5 minutes if ambient temperature is less than 30 °c. If ambient ...

  • Page 85

    Technical data 85 symbols sizing the current ratings are the same regardless of the supply voltage within one voltage range. 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. Note 1:the maximum allowed motor s...

  • Page 86

    Technical data 86 fuses gg and ar fuses for protection against short-circuit in the input power cable or drive are listed below. Either fuse type may be used if it operates rapidly enough. Choose between gg and ar fuses according to the table under quick guide for selecting between gg and ar fuses o...

  • Page 87

    Technical data 87 the calculated short-circuit current 9.7 ka is higher than the minimum short-circuit current of the drive gg fuse type ofaf3h500 (8280 a). -> the 500 v gg fuse (abb control ofaf3h500) can be used. Fuse tables gg fuses acs800-04 size input current min. Short- circuit current 1) fuse...

  • Page 88

    Technical data 88 three-phase supply voltage 380 v, 400 v, 415 v, 440 v, 460 v, 480 v or 500 v -0170-5 191 3820 250 550 000 500 abb control ofaf1h250 1 -0210-5 243 4510 315 1 100 000 500 abb control ofaf2h315 2 -0260-5 291 4510 315 1 100 000 500 abb control ofaf2h315 2 -0320-5 424 8280 500 2 900 000...

  • Page 89

    Technical data 89 ultrarapid (ar) fuses acs800-04 size input current a min. Short- circuit current 1) fuse a a a 2 s v manufacturer type din 43620 size three-phase supply voltage 208 v, 220 v, 230 v or 240 v -0080-2 201 1810 400 105 000 690 bussmann 170m3819 din1* -0100-2 239 2210 500 145 000 690 bu...

  • Page 90

    Technical data 90 a 2 s value for -7 units at 660 v 1) minimum short-circuit current of the installation note 1: see also planning the electrical installation : thermal overload and short-circuit protection . For ul recognized fuses, see nema data on page 94 . Note 2: in multicable installations, in...

  • Page 91

    Technical data 91 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. Note...

  • Page 92

    Technical data 92 note 2: the table is not intended for transformer selection - that must be done separately. The following parameters can effect on the correct operation of the protection: • cable length, i.E. The longer the cable the weaker the fuse protection, as the long cable limits the fault c...

  • Page 93

    Technical data 93 cable entries mains, motor and brake resistor cable terminal sizes (per phase), maximum accepted cable and tightening torques are given below. Dimensions, weights and noise h height w1 width of the basic unit with pe terminal (bookshelf) w2 width with the cable connection terminal ...

  • Page 94: Nema Data

    Technical data 94 nema data ratings the nema ratings for the acs800-u4 and acs800-04 with 60 hz supplies are given below. The symbols are described below the table. For sizing, derating and 50 hz supplies, see iec data . 1) available if ambient temperature is less than 30 °c (86 °f). If ambient temp...

  • Page 95

    Technical data 95 3) 50% overload is allowed for one minute every five minutes if ambient temperature is less than 30 °c (86 °f). 40% overload is allowed if ambient temperature is 40 °c (104 °f). 4) available if ambient temperature is less than 30 °c (86 °f). If ambient temperature is 40 °c (104 °f)...

  • Page 96

    Technical data 96 ul class t and l fuses acs800-u4 type input current fuse a a v manufacturer type ul class three-phase supply voltage 208 v, 220 v, 230 v, 240 v -0080-2 201 250 600 bussmann jjs-250 t -0100-2 239 300 600 bussmann jjs-300 t -0120-2 285 400 600 bussmann jjs-400 t -0140-2 391 500 600 b...

  • Page 97

    Technical data 97 cable types 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 a...

  • Page 98

    Technical data 98 dimensions, weights and noise h height w1 width of the basic unit with pe terminal (bookshelf) w2 width with the cable connection terminal plates on the left side only (bookshelf) d depth without fastening brackets (r7 bookshelf: depth with fastening brackets is 20.32 in.) (r8 book...

  • Page 99: Input Power Connection

    Technical data 99 input power connection voltage (u 1 ) 208/220/230/240 vac 3-phase± 10% for 230 vac units 380/400/415 vac 3-phase± 10% for 400 vac units 380/400/415/440/460/480/500 vac 3-phase± 10% for 500 vac units 525/550/575/600/660/690 vac 3-phase± 10% for 690 vac units rated conditional short-...

  • Page 100: Ambient Conditions

    Technical data 100 prevention of unexpected start: agps-21 board nominal input voltage 115 vac or 230 vac input voltage range (selected by jumper) 95...132 vac (x3 on), 185...265 vac (x4 on, default) nominal frequency 50/60 hz current 0.77 a at 115 v, 0.44 a at 230 v max. External fuse 16 a input co...

  • Page 101: Materials

    Technical data 101 materials drive enclosure • pc/abs 2.5 mm, colour ncs 1502-y (ral 90021 / pms 420 c) • hot-dip zinc coated steel sheet 1.5 to 2.5 mm, thickness of coating 100 micrometres, colour ncs 1502-y package plywood and wood. Plastic covering of the package: pe-ld, bands pp or steel. Dispos...

  • Page 102: Ce Marking

    Technical data 102 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 electromagneti...

  • Page 103

    Technical data 103 second environment (drive of category c3) the drive complies with the standard with the following provisions: 1. The drive is equipped with emc filter +e210. The filter is suitable for tn (earthed) and it (unearthed) systems. 2. The motor and control cables are selected as specifi...

  • Page 104: “C-Tick” Marking

    Technical data 104 “c-tick” marking “c-tick” marking is required in australia and new zealand. A “c-tick” mark is attached to each drive in order to verify compliance with the relevant standard (iec 61800-3 (2004) – adjustable speed electrical power drive systems – part 3: emc product standard inclu...

  • Page 105

    Technical data 105 second environment (drive of category c3) the drive complies with the standard with the following provisions: 1. The drive is equipped with emc filter +e210. The filter is suitable for tn (earthed) and it (unearthed) systems. 2. The motor and control cables are selected as specifi...

  • Page 106: Ul/csa Markings

    Technical data 106 ul/csa markings the acs800-04, acs800-u4 and acs800-04m are c-ul us listed and csa marked. The approval is valid with rated voltages (up to 600 v). Ul the drive is suitable for use on a circuit capable of delivering not more than 100 ka rms symmetrical amperes at the drive nominal...

  • Page 107: Resistor Braking

    Resistor braking 107 resistor braking what this chapter contains this chapter describes how to select, protect and wire brake choppers and resistors. The chapter also contains the technical data. To which products this chapter applies this chapter applies to the acs800-01/u1 (frame sizes r2 to r6), ...

  • Page 108

    Resistor braking 108 note: a resistor other than the standard resistor can be used provided that: • its resistance is not lower than the resistance of the standard resistor. Warning! Never use a brake resistor with a resistance below the value specified for the particular drive / brake chopper / res...

  • Page 109

    Resistor braking 109 400 v units -0003-3 1.1 sace08re44 44 210 1 -0004-3 1.5 sace08re44 44 210 1 -0005-3 2.2 sace08re44 44 210 1 -0006-3 3.0 sace08re44 44 210 1 -0009-3 4.0 sace08re44 44 210 1 -0011-3 5.5 sace15re22 22 420 2 -0016-3 7.5 sace15re22 22 420 2 -0020-3 11 sace15re22 22 420 2 -0025-3 23 s...

  • Page 110

    Resistor braking 110 p brcont the drive and the chopper will withstand this continuous braking power. The braking is considered continuous if the braking time exceeds 30 s. Note: check that the braking energy transmitted to the specified resistor(s) in 400 seconds does not exceed e r . R resistance ...

  • Page 111: 04M/u4 And Acs800-07/u7

    Resistor braking 111 optional brake chopper and resistor(s) for the acs800-02/u2, acs800-04/ 04m/u4 and acs800-07/u7 the nominal ratings for dimensioning the brake resistors for the acs800-02/u2, acs800-04/04m/u4 and acs800-07/u7 are given below at an ambient temperature of 40 °c (104 °f). Acs800 ty...

  • Page 112

    Resistor braking 112 690 v units -0070-7 r6 - - - 45 safur90f575 8.00 1800 4.5 -0100-7 r6 - - - 55 safur80f500 6.00 2400 6 -0120-7 r6 - - - 75 safur80f500 6.00 2400 6 -0140-7 r7 125 5) 110 90 75 safur80f500 6.00 2400 6 -0170-7 r7 125 6) 110 90 75 safur80f500 6.00 2400 6 -0210-7 r7 125 6) 110 90 75 s...

  • Page 113

    Resistor braking 113 all braking resistors must be installed outside the converter module. The resistors are built in an ip 00 metal frame. The 2xsafur and 4xsafur resistors are connected in parallel. Note: the safur resistors are not ul listed. Resistor installation and wiring all resistors must be...

  • Page 114

    Resistor braking 114 use the cable type used for drive input cabling (refer to chapter technical data) to ensure the input fuses will also protect the resistor cable. Alternatively, two- conductor shielded cable with the same cross-sectional area can be used. The maximum length of the resistor cable...

  • Page 115

    Resistor braking 115 with standard control program, wire the thermal switch as shown below. By default, the drive will stop by coasting when the switch opens. For other control programs, the thermal switch may be wired to a different digital input. Programming of the input to trip the drive by “exte...

  • Page 116

    Resistor braking 116.

  • Page 118

    3a f e 64 671 006 rev f e n effe ctive : 1 5.6 .2007 abb oy ac drives p.O. Box 184 fi-00381 helsinki finland telephone +358 10 22 11 fax +358 10 22 22681 internet www.Abb.Com abb inc. Automation technologies drives & motors 16250 west glendale drive new berlin, wi 53151 usa telephone 262 785-3200 80...