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ABB ACS800 Hardware Manual
Summary of ACS800
Page 1
Acs800 hardware manual acs800-07 (+v992) drives (500 to 2800 kw).
Page 2: Acs800-07 Manuals
Acs800-07 manuals hardware manual acs800-07 (+v992) drives (500 to 2800 kw) hardware manual 3aua0000068936 1) supply unit firmware manual acs800 diode supply control program firmware manual 3aua0000068937 1) inverter unit firmware manual (drive application program firmware manual) standard control p...
Page 3: Hardware Manual
Acs800-07 (+v992) drives 500 to 2800 kw hardware manual 3aua0000068936 rev a en effective: 2010-03-15 © 2010 abb oy. All rights reserved..
Page 5: Safety Instructions
Safety instructions 5 safety instructions what this chapter contains this chapter contains safety instructions you must follow when installing, operating and servicing the drive. If ignored, physical injury or death may follow, or damage may occur to the drive, the motor or driven equipment. Read th...
Page 6: •
Safety instructions 6 installation andmaintenance work these warnings are intended for all who work on the drive, motor cable or motor. Ignoring the instructions can cause physical injury or death, or damage the equipment. Warning! • only qualified electricians are allowed to install and maintain th...
Page 7: •
Safety instructions 7 note: • the main disconnecting device (main breaker or main switch-disconnector) does not switch off the voltage from the auxiliary circuits or the input busbars. • the motor cable terminals on the drive are at a dangerously high voltage when the input power is on, regardless o...
Page 8: •
Safety instructions 8 grounding these instructions are intended for all who are responsible for the grounding of the drive. Incorrect grounding can cause physical injury, death or equipment malfunction and increase electromagnetic interference. Fibre optic cables warning! • ground the drive, motor a...
Page 9: Operation
Safety instructions 9 operation these warnings are intended for all who plan the operation of the drive or operate the drive. Ignoring the instructions can cause physical injury or death or damage the equipment. Warning! • if the drive is equipped with an optional brake unit, make sure there are inv...
Page 10
Safety instructions 10 permanent magnet motor drives these are additional warnings concerning permanent magnet motor drives. Warning! Do not work on the drive when the permanent magnet motor is rotating. Also when the supply power is switched off, a rotating permanent magnet motor feeds power to the...
Page 11: Table of Contents
Table of contents 11 table of contents acs800-07 manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 safety instructions what this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 12
Table of contents 12 other operating switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 analog and...
Page 13
Table of contents 13 protection against short-circuit inside the drive or in the supply cable . . . . . . . . . . . . . . . . . 62 ground fault protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 emergency stop devices . ....
Page 14
Table of contents 14 or main breaker (option +f253 or +f255) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 six-pulse connect...
Page 15
Table of contents 15 on-load checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 maintenance what this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 16
Table of contents 16 motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132 efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 17
Table of contents 17 resistor braking what this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 resistor braking options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 18
Table of contents 18.
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 gives safety instructions for the installation, commissioning, operation and maintenance of the drive. About this manual introduces this manual. Hardware description describes the drive. Mechan...
Page 21
About this manual 21 installation and commissioning flowchart task see plan the installation. Check the ambient conditions, ratings, required cooling air flow, input power connection, compatibility of the motor, motor connection, and other technical data. Select the cables. Technical data planning t...
Page 22: Terms and Abbreviations
About this manual 22 terms and abbreviations term/abbreviation explanation adpi control panel interface board apbu branching unit used for making parallel connections for both supply units and inverter modules bamu main voltage measurement board cdp312r control panel cint module interface board cmib...
Page 23
About this manual 23 rdcu drive control unit the rdcu consists of a control board (rmio) enclosed inside a plastic casing for an easy snap-on installation. There are two rdcus in a large single drive: one for the supply unit (supply unit control board) and the other for the inverter unit (inverter u...
Page 24
About this manual 24.
Page 25: Hardware Description
Hardware description 25 hardware description what this chapter contains this chapter describes the construction of the drive in short. Acs800-07 (+v992) acs800-07 (+v992) is a cabinet-mounted drive for controlling ac motors. Cabinet line-up the drive consists of several cubicles that contain the sup...
Page 26
Hardware description 26 single-line circuit diagram of the drive, example 1 m voltage measurement (bamu) 400 vac 230/115 vac m 3~ input power line 400 vac notes: the diagram shows drive type acs800-07-0610-3+f250 comprising: – one dsu module and inverter module (d4 + r8i) – main switch-disconnectors...
Page 27
Hardware description 27 single-line circuit diagram of the drive, example 2 m voltage measurement (bamu) 400 vac m 230/115 vac m 3~ main supply 400 vac 400 vac notes: the diagram shows drive type acs800-07-0870-3+f250+f253+f260 comprising: – two parallel dsu modules and two parallel inverter modules...
Page 28: Layout Drawing, Example 1
Hardware description 28 layout drawing, example 1 the following drawing shows an acs800-07-0610-3+f250 drive type comprising: • one dsu module and two parallel inverter modules (1×d4 + 2×r8i) • main switch-disconnector inside the dsu module (internal main switch- disconnectors) • main contactors (op...
Page 29: Layout Drawing, Example 2
Hardware description 29 layout drawing, example 2 the following drawing shows drive type acs800-07-0870-3+f253+f259+f260 comprising: • two parallel dsu modules and two parallel inverter modules (2×d4 + 2×r8i) • optional main switch-disconnector (option +f253) and grounding switch (option +f259) • ma...
Page 30
Hardware description 30 no. Description 1 input busbars. 2 main switch-disconnector (option +f253) in a dedicated cubicle. 3 grounding switch (option +f259). 4 ac fuses. Only present if the drive is equipped with a main switch-disconnector or main breaker. 5 supply modules. + behind each module: qui...
Page 31: Swing-Out Frame
Hardware description 31 swing-out frame the swing-out frame inside the auxiliary control cubicle provides space for the inverter unit control board, control electronics of the drive, i/o terminal blocks, and optional electrical equipment. The lead-throughs for i/o cables, the auxiliary voltage trans...
Page 32
Hardware description 32 power connections and control interfaces of the drive the following diagram illustrates the power connections and control interfaces of the drive. The table below gives some additional information on the numbered items. No. Description see also page 1 input power and pe conne...
Page 33
Hardware description 33 controls of the inverter unit (and motor) the inverter control program runs in the rdcu control unit located in the swing-out frame. The rdcu is connected to the inverter modules by a fibre optic link, distributed through an optical branching unit. In the inverter modules, th...
Page 34: Controls of The Supply Unit
Hardware description 34 controls of the supply unit the supply unit control program runs in the rdcu control unit located in the swing- out frame. The rdcu is connected to the supply modules by a fibre optic link, and a separate wire set. If there are parallel supply modules, the controls from the r...
Page 35
Hardware description 35 note: on units without the line contactor option (+f250), main breaker option (+f255) or the main switch-disconnector option (+f253), the supply unit will start rectifying as soon as the user closes the switch-disconnector(s) of the supply module(s). There is no separate oper...
Page 36
Hardware description 36 the default cable connections to the rmio board of the dsu are shown below. X20 1 vref- reference voltage -10 vdc, 1 kohm r l 2 gnd x21 1 vref+ reference voltage 10 vdc, 1 kohm r l 2 gnd 3 ai1+ by default, not in use. 0(2) …10 v, r in > 200 kohm 4 ai1- 5 ai2+ by default, not ...
Page 37: Ground Fault Monitoring
Hardware description 37 fieldbus for more information on the fieldbus communication, see acs800 diode supply control program firmware manual (3aua0000068937[english]). Power loss ride-through function the power loss ride-through function keeps the supply unit operative over an unexpected input power...
Page 38: Type Designation
Hardware description 38 type designation the type code of the drive is indicated on the type designation label, attached on a door of the supply unit. The type code contains information on the specifications and configuration of the drive. The first digits from left express the basic configuration (...
Page 39
Hardware description 39 line options f250 = main contactors inside the dsu modules f253+f260 = ar ac fuses + main switch-disconnector (6-pulse) (main switch-disconnectors in dsu modules removed) a004+f253+f260 = ar ac fuses + main switch-disconnector (12-pulse) (main switch-disconnectors in supply m...
Page 40
Hardware description 40 safety features q950 = prevention of unexpected start-up (category 3) q951 = emergency stop, stop category 0 with opening the main contactor/breaker q952 = emergency stop, stop category 1 with opening the main contactor/breaker q954 = ground fault monitoring (it [ungrounded] ...
Page 41: Mechanical Installation
Mechanical installation 41 mechanical installation what this chapter contains this chapter describes the mechanical installation procedure of the drive. General see chapter technical data for allowable operating conditions and requirements for free space around the unit. The unit should be installed...
Page 42: Moving The Unit
Mechanical installation 42 moving the unit …by crane use the steel lifting lugs attached to the top of the cabinet. Insert the lifting ropes or slings into the holes of the lifting lugs. The lifting lugs can be removed (not mandatory) once the cabinet is in its final position. If the lifting lugs ar...
Page 43
Mechanical installation 43 …by fork-lift or pallet truck …on rollers (not allowed with marine versions) laying the unit on its back the center of gravity may be quite high. Be therefore careful when transporting the unit. Tilting the cabinets must be avoided. The units are to be moved only in the up...
Page 44
Mechanical installation 44 final placement of the unit the cabinet can be moved into its final position with an iron bar and a wooden piece at the bottom edge of the cabinet. Care is to be taken to properly place the wooden piece so as not to damage the cabinet frame..
Page 45: Before Installation
Mechanical installation 45 before installation delivery check the drive delivery contains: • drive cabinet line-up • optional modules (if ordered) installed into the control rack at the factory • ramp for extracting supply and inverter modules from the cabinet • hardware manual • appropriate firmwar...
Page 46: Installation Procedure
Mechanical installation 46 installation procedure see detailed instructions in the following few pages. (1) the cabinet can be installed with its back against a wall, or back-to-back with another unit. Fasten the unit (or first shipping split) to the floor with fastening clamps or through the holes ...
Page 47
Mechanical installation 47 fastening the cabinet to the floor (non-marine units) the cabinet is to be fastened to the floor by using clamps along the edge of the cabinet bottom, or by bolting the cabinet to the floor through the holes inside. Clamping insert the clamps into the twin slots along the ...
Page 48
Mechanical installation 48 holes inside the cabinet the cabinet can be fastened to the floor using the fastening holes inside the cabinet, if they are accessible. The recommended maximum distance between the fastening points is 800 mm (31.5”). If there is not enough working space behind the cabinet ...
Page 49
Mechanical installation 49 fastening the unit to the floor and wall (marine units) the unit must be fastened to the floor and roof (wall) as follows: use m10 or m12 screws; welding is not recommended (see section electric welding below). 1 2 3 1 2 3 bolt the unit to the floor through the holes in ea...
Page 50: Joining The Shipping Splits
Mechanical installation 50 joining the shipping splits the busbar systems and wiring harnesses of two shipping splits are joined in the common motor terminal cubicle (if present) or a busbar joining cubicle. Special m6 screws for fastening the shipping splits together are enclosed in a plastic bag i...
Page 51
Mechanical installation 51 • remove any intermediate or partitioning plates covering the rear posts of the joining cubicle. • fasten the rear post of the joining section with seven screws (below the busbar joining part) to the rear post of the next cubicle. • replace all partitioning plates in the u...
Page 52
Mechanical installation 52 dc busbars the dc busbar connection is shown below. Pe busbar the pe busbar runs continuously through the line-up near the floor at the back. The connection is shown below. No separate nuts are needed. Tighten the bolts to 55–70 nm (40–50 ft.-lbs.) side view of single busb...
Page 53: Miscellaneous
Mechanical installation 53 miscellaneous cable duct in the floor below the cabinet a cable duct can be constructed below the 400 mm wide middle part of the cabinet. The cabinet weight lies on the two 100 mm wide transverse sections which the floor must carry. Viewed from above side view this area ca...
Page 54
Mechanical installation 54 cooling air intake through bottom of cabinet units with air intake through the bottom of the cabinet (optional feature) are intended for installation on an air duct in the floor. The required air inlets in the floor are as listed below. Refer also to the dimensional drawin...
Page 55
Mechanical installation 55 electric welding it is not recommended to fasten the cabinet by welding. Cabinets without flat bars at the base • connect the return conductor of the welding equipment to the cabinet frame at the bottom within 0.5 metres of the welding point. Cabinets with flat bars at the...
Page 56
Mechanical installation 56.
Page 57: What This Chapter Contains
Planning the electrical installation 57 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 58
Planning the electrical installation 58 4. Consult the motor manufacturer before using a motor in a drive system where the motor nominal voltage differs from the ac power source voltage. 5. Ensure that the motor insulation system withstands the maximum peak voltage in the motor terminals. See the re...
Page 59
Planning the electrical installation 59 * 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 will be increased from the nominal level by resistor braking or by...
Page 60
Planning the electrical installation 60 note 1:the abbreviations used in the table are defined below. 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: h...
Page 61
Planning the electrical installation 61 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 62
Planning the electrical installation 62 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 63: Ground Fault Protection
Planning the electrical installation 63 ground fault protection the inverter unit is equipped with an internal ground fault protective function to protect the drive against ground faults in the drive, motor and motor cable (this is not a personal safety or a fire protection feature). The ground faul...
Page 64
Planning the electrical installation 64 prevention of unexpected start-up the drive can be equipped with an optional prevention of unexpected start-up function according to standards iec/en 60204-1: 1997; iso/dis 14118: 2000 and en 1037: 1996. The circuit conforms to en954-1, category 3. The functio...
Page 65: Safe Torque Off
Planning the electrical installation 65 safe torque off the drive supports the safe torque off (sto) function according to standards en 61800-5-2: 2007; en/iso 13849-1: 2008, en 60204-1: 2006; iec 61508, en 1037: 1995 + a1: 2008 and en 62061: 2005. The function also corresponds to an uncontrolled st...
Page 66: Selecting The Power Cables
Planning the electrical installation 66 selecting the power cables general rules dimension the supply (input power) and motor cables according to local regulations: • the cable must be able to carry the drive load current. See chapter technical data for the rated currents. • the cable must be rated ...
Page 67
Planning the electrical installation 67 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 68
Planning the electrical installation 68 conduit where conduits must be coupled together, bridge the joint with a ground conductor bonded to the conduit on each side of the joint. Bond the conduits also to the drive enclosure. Use separate conduits for input power, motor, brake resistors, and control...
Page 69
Planning the electrical installation 69 power factor compensation capacitors power factor compensation is not needed with ac drives. However, if a drive is to be connected to a system with compensation capacitors already installed, note the following restrictions. Warning! Do not connect power facto...
Page 70
Planning the electrical installation 70 before opening an output contactor (in the dtc motor control mode) stop the drive and wait for the motor to stop before opening a contactor between the output of the drive and the motor when the dtc control mode is selected. (see the firmware manual of the dri...
Page 71: Selecting The Control Cables
Planning the electrical installation 71 selecting the control cables all control cables must be shielded. Use a double-shielded twisted pair cable (see figure a) for analogue signals. This type of cable is recommended for the pulse encoder signals also. Employ one individually shielded pair for each...
Page 72
Planning the electrical installation 72 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 73: Routing The Cables
Planning the electrical installation 73 routing the cables route the motor cable away from other cable routes. Motor cables of several drives can be run in parallel installed next to each other. It is recommended that the motor cable, input power cable and control cables be installed on separate tra...
Page 74
Planning the electrical installation 74.
Page 75: Electrical Installation
Electrical installation 75 electrical installation what this chapter contains this chapter describes the electrical installation procedure of the drive. Warning! Only qualified electricians are allowed to carry out the work described in this chapter. Follow the safety instructions on the first pages...
Page 76
Electrical installation 76 motor and motor cable check the insulation of the motor and motor cable as follows: 1. Check that the motor cable is connected to the motor, and disconnected from the drive output terminals u2, v2 and w2. 2. Measure the insulation resistance between each phase conductor an...
Page 77
Electrical installation 77 input power connection – units without main switch-disconnector or main breaker (no option +f253 or +f255) connection diagrams six-pulse connection, two dsu modules in parallel l11 l21 l31 l12 l22 l32 pe notes: • no parallel cabling is shown here. • each input terminal of ...
Page 78
Electrical installation 78 twelve-pulse connection, two dsu modules in parallel l11 l21 l31 l12 l22 l32 pe * ) notes: • no parallel cabling (for each module) is shown here. It is also possible to connect all input power terminals of module 1 to the transformer y-output and module 2 to the transforme...
Page 79
Electrical installation 79 connection procedure warning! Read and follow the instructions given in safety instructions . Ignoring the instructions can cause physical injury or death, or damage to the equipment. Warning! The supply modules are heavy and have a high center of gravity. Be careful when ...
Page 80
Electrical installation 80 3. Disconnect the module signal wire set. (c) the counterpart must be used and connected to the wire set instead of the dsu module, when the module is removed from the cabinet. 4. Unplug also the pair of fibre optic cables from its connectors on the front of the dsu module...
Page 81
Electrical installation 81 7. Pull the module carefully out of the cabinet along the ramp. (h) phase 2 – installing the cables 1. Remove the plastic insulators covering the input power terminals. G g f h.
Page 82
Electrical installation 82 2. Lead the cables into the inside of the cabinet. Make the 360° grounding arrangement at the cable entries as shown below. 3. Connect the cables as follows: - twist the cable shields to bundles and connect to the cabinet pe (ground) busbar. Connect the separate ground con...
Page 83
Electrical installation 83 use of the dual-cable screw lug connector removal of the dual-cable screw lug connector 1 2 3 4 1 2 3.
Page 84
Electrical installation 84 input power connection – units with main switch-disconnector or main breaker (option +f253 or +f255) connection diagrams six-pulse connection, two dsu modules in parallel pe * ) notes: * ) fuses are not required if the input power line is constructed of busbars that withst...
Page 85
Electrical installation 85 twelve-pulse connection, two dsu modules in parallel pe * ) notes: when the same 12-pulse transformer is used to supply more than one module, connect the dc outputs of all modules to a common dc link. Separate links will cause current unbalance fault trips due to circulati...
Page 86
Electrical installation 86 connection procedure warning! Read and follow the instructions given in safety instructions . Ignoring the instructions can cause physical injury or death, or damage to the equipment. Open the door of the incoming (main switch-disconnector or main breaker) cubicle. Remove ...
Page 87: Option +H359)
Electrical installation 87 motor connection – units without common motor terminal cubicle (no option +h359) the motor cables are to be connected to the output busbars behind each inverter module. The location and dimensions of the busbars are visible in the dimensional drawings delivered with the dr...
Page 88
Electrical installation 88 warning! The cabling from all inverter modules to the motor must be physically identical considering cable type, cross-sectional area, and length. Pe inverter module cubicle u2 v2 w2 u2 v2 w2 m 3~ u1 w1 v1 pe.
Page 89
Electrical installation 89 connection procedure warning! Read and follow the instructions given in safety instructions. Ignoring the instructions can cause physical injury or death, or damage to the equipment. Warning! The supply modules are heavy and have a high center of gravity. Be careful when m...
Page 90
Electrical installation 90 lead the cables into the cabinet below each inverter module. Make the 360° grounding arrangement at the cable entry as shown. Cut the cables to suitable length. Strip the cables and conductors. Twist the cable screens into bundles and connect to cabinet pe (ground) busbar....
Page 91: (Option +H359)
Electrical installation 91 motor connection – units with common motor terminal cubicle (option +h359) connection diagram connection procedure see the connection procedure on page 90. U2 v2 w2 pe the recommended cable types are given in chapter planning the electrical installation . M 3~ u1 w1 v1 pe ...
Page 92: Control Connections
Electrical installation 92 control connections drive/inverter control connections the control connections are made on the terminal blocks provided in the swing-out frame in the auxiliary control cubicle of the drive. Refer to the circuit diagrams delivered with the drive, and to the chapter motor co...
Page 93
Electrical installation 93 connection procedure turn the main switch-disconnector into open position (or rack the withdrawable main breaker out). Release the door handle and open the door of the auxiliary control cubicle. Remove the two locking screws at the edge of the swing-out frame and open the ...
Page 94
Electrical installation 94 run the cables to the swing-out frame as shown below. Wherever possible, use the existing cable trunking (1) in the cabinet. Use sleeving wherever the cables are laid against sharp edges. Leave some slack in the cable at the hinge (2) to allow the frame to open fully. Tie ...
Page 95
Electrical installation 95 installation of optional modules and pc the optional module (such as fieldbus adapter, i/o extension module and the pulse encoder interface) is inserted into the optional module slot of the inverter unit control board (rdcu) and fixed with two screws . See the appropriate ...
Page 96: Of The Drive
Electrical installation 96 connections and tap settings of the auxiliary voltage transformer of the drive 3~ input primary se cond ary 3~ input 1~ output 3~ output supply voltage terminals tap settings supply voltage 230 v 400 v (50 hz) 320 v (60 hz) a1 to... B1 to… c1 to… terminals tap setting term...
Page 97
Electrical installation 97 switching on and selecting the supply voltage of the auxiliary voltage transformer of the dsu module 1. Detach the lid which covers the switches and selector of the auxiliary voltage transformer of the dsu module. The lid is on the front cover of the module. In the figure ...
Page 98
Electrical installation 98.
Page 99: What This Chapter Contains
Motor control and i/o board (rmio) 99 motor control and i/o board (rmio) what this chapter contains this chapter shows • external control connections to the control board of the inverter unit with the acs800 standard control program (factory macro) • specifications of the inputs and outputs of the b...
Page 100
Motor control and i/o board (rmio) 100 external control connections (non-us) external control cable connections to the rmio board for the acs800 drive control program (factory macro) are shown below. For external control connections of other application macros and programs, see the appropriate firmw...
Page 101
Motor control and i/o board (rmio) 101 external control connections (us) external control cable connections to the rmio board for the acs800 drive control program (factory macro us version) are shown below. For external control connections of other application macros and programs, see the appropriat...
Page 102: Rmio Board Specifications
Motor control and i/o board (rmio) 102 rmio board specifications analogue inputs with the drive 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 an...
Page 103
Motor control and i/o board (rmio) 103 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 isolation test voltage 4 kvac, 1 minute ddcs fibre optic link with opti...
Page 104
Motor control and i/o board (rmio) 104 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 r...
Page 105: Installation Checklist
Installation checklist and start-up 105 installation checklist and start-up installation checklist check the mechanical and electrical installation of the drive before start-up. Go through the checklist below together with another person. Read the safety instructions on the first pages of this manua...
Page 106: Start-Up Procedure
Installation checklist and start-up 106 start-up procedure this section instructs how to start-up the acs800-07 drive. The instructions do not cover all possible tasks of all possible variants of the drive as the compositon of the make-to-order drives vary. Always refer to the delivery-specific circ...
Page 107
Installation checklist and start-up 107 connecting voltage to input terminals and auxiliary circuit warning! When voltage is connected to the input terminals, voltage may also be connected to the auxiliary circuits of the drive unit(s). Make sure that it is safe to apply voltage. Ensure that: • nobo...
Page 108
Installation checklist and start-up 108 close the main contactors (option +f250] or the main breaker [q1] (option +f255), and start the dsu: turn the three-position operating switch [s11] on the cabinet door from 0 to the start position for 2 s. Setting up the supply unit control program check the s...
Page 109: Maintenance
Maintenance 109 maintenance what this chapter contains this chapter contains preventive maintenance instructions. Maintenance intervals this table lists the routine maintenance intervals recommended by abb. Consult your local abb service representative for more details on the maintenance. On the int...
Page 110
Maintenance 110 redundancy (reduced run capability) if one of the parallel-connected supply or inverter modules must be taken out of the cabinet for service, it is possible to continue operation using the remaining modules at reduced power. Removing a dsu module and selecting the reduced run feature...
Page 111
Maintenance 111 5. Close the cabinet doors. 6. Switch on the auxiliary control voltage of the drive. 7. Switch the panel from the inverter unit to the dsu. The supply and inverter units are connected to the same panel through a panel link. The panel communicates with either one at the time. The swit...
Page 112
Maintenance 112 removing an inverter module and selecting the reduced run feature warning! Read and follow the instructions in chapter safety instructions . Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Switch off the power to the unit and open the main...
Page 113
Maintenance 113 replacing the ppcs branching unit (apbu-xx) memory backup battery warning! Read and follow the instructions in chapter safety instructions . Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Switch off the power to the unit and open the main...
Page 114
Maintenance 114 checking and replacing the air filters warning! Read and follow the instructions in chapter safety instructions . Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Switch off the power to the unit and open the main disconnecting device. Clos...
Page 115: Cooling Fans
Maintenance 115 cooling fans supply, inverter and brake module cooling fans the actual lifespan of the fan depends on the running time of the fan, ambient temperature and dust concentration. Each supply and inverter module has its own cooling fan. Replacements are available from abb. Do not use othe...
Page 116
Maintenance 116 replacing the fan of the inverter and brake module warning! Read and follow the instructions in chapter safety instructions . Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Switch off the power to the unit and open the main disconnecting ...
Page 117
Maintenance 117 replacing the fans in the auxiliary control cubicle warning! Read and follow the instructions in chapter safety instructions . Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Switch off the power to the unit and open the main disconnecting...
Page 118
Maintenance 118 replacing the fan in the incoming cubicle with the main breaker (option +f255) certain ip2x/ip4x (+b053 and +b054) units with a main breaker are also fitted with two fans at the air outlet on the roof. Replace the fans as follows: warning! Read and follow the instructions in chapter ...
Page 119
Maintenance 119 replacing the additional fans in the ip54 / ul type 12 drives (+b055 and +b059) warning! Read and follow the instructions in chapter safety instructions . Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Switch off the power to the unit and...
Page 120
Maintenance 120 3 4 5 4 4 4 5 6 7 7 9 8 13 13 14 12 10 10 10 10 11 11.
Page 121: Heatsinks
Maintenance 121 heatsinks the heatsink fins of the power modules pick up dust from the cooling air. The module runs into overtemperature warnings and faults if the heatsinks are not clean. In a “normal” environment (not especially dusty nor clean) the heatsinks should be checked annually, in a dusty...
Page 122: Other Maintenance Actions
Maintenance 122 safety function checks in the maintenance routine it is a good practice to check the operation of the optional safety functions at appropriate intervals. If the drive is equipped with optional safety functions +q950, +q951, +q952, +q954, +q963, +q964 or q968, include the safety funct...
Page 123: Fault Tracing
Fault tracing 123 fault tracing what this chapter contains this chapter instructs in interpreting the led indications of the acs800-07 (+v992) drive. Note: information on warnings and faults reported by the application program (and displayed on the control panel on the cabinet door) are contained wi...
Page 124: Other Leds of The Drive
Fault tracing 124 other leds of the drive location led indication rmio board (rdcu control unit) red drive in the fault state. Green power supply on the board is ok. Control panel mounting platform (with the control panel removed) red drive in the fault state. Green main + 24 v power supply for the ...
Page 125: Technical Data
Technical data 125 technical data what this chapter contains this chapter contains the technical specifications of the drive, eg, ratings, frame sizes and technical requirements, provisions for fulfilling the requirements for ce and other markings. Ratings the ratings for the acs800-07 (+v992) with ...
Page 126
Technical data 126 symbols derating the load capacity (current and power) decreases if the installation site altitude exceeds 1000 metres (3281 ft), or if the ambient temperature exceeds 40 °c (104 °f). Temperature derating in the temperature range +40 °c (+104 °f) to +50 °c (+122 °f), the rated out...
Page 127
Technical data 127 acs800-07 (+v992) frame sizes and power module types acs800-07 (+v992) type frame size (supply+inverter modules) supply module(s) used inverter modules used qty type qty type three-phase supply voltage 380 v, 400 v or 415 v acs800-07-0610-3 1×d4 + 2×r8i 1 acs800-704-0910-7 2 acs80...
Page 128: Ac Fuses
Technical data 128 ac fuses acs800- 07+v992… type input current (a) qty. Type (iec/ul/csa) rated current (a rms) voltage (v) i 2 t pre-arc i 2 t clearing at 660v i 2 t clearing at 210000 [a2s] u n = 400 v (range 380-415 v) -0610-3 790 6 170m6410 bussmann 630 690 31000 210000 210000 -0770-3 999 12 -0...
Page 129: Fuses On The Cvar Board
Technical data 129 dc fuses at inverter module input fuses for main circuit voltage measurement for the bamu board the fuse type is ferraz a070grc01t13, 1 a 700 v ac 160 ka. Fuses on the cvar board the fuse type is ferraz a070grb10t13/g330010 10 a 700 v ac. Dc fuses for the dsu module each d4 type d...
Page 130: Input Power Connection
Technical data 130 input power connection voltage (u 1 ) 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 short-circuit withstand strength (iec 60439-1) drives without grounding sw...
Page 131
Technical data 131 input terminals at each supply module (units without main switch-disconnector or main breaker; no option +f253 or +f255) input terminals (units with main switch-disconnector or main breaker; option +f253 or +f255) conductor size max. No. And size of cable lugs per phase lug hole b...
Page 132: Motor Connection
Technical data 132 motor connection voltage (u 2 ) 0 to u 1 ,3-phase symmetrical, u max at the field weakening point frequency dtc mode: 0 to 3.2 × f fwp . Maximum frequency 300 hz. F fwp = where f fwp = frequency at field weakening point; u nmains = mains (input power) voltage; u nmotor = rated mot...
Page 133: Efficiency
Technical data 133 output terminals at each r8i inverter module (units without common motor terminal cubicle, no option +h359) output terminals (units with common motor terminal cubicle, option +h359) 8 × Ø13 mm per phase. See the chapter dimensions . Maximum recommended motor cable length 100 m (32...
Page 134: Cooling
Technical data 134 cooling method internal fans, flow direction from bottom to top filter material inlet (door) outlet (roof) ip22/ip42 units (+b053 and +b054) luftfilter airtex g150 – ip54 units (+b055 and +b059) luftfilter aircomp 300-50 luftfilter airtex g150 free space around the unit see chapte...
Page 135: Materials
Technical data 135 contamination levels (iec 60721-3-3, iec 60721-3- 2, iec 60721-3-1) no conductive dust allowed. Boards without coating: chemical gases: class 3c1 solid particles: class 3s2 boards with coating: chemical gases: class 3c2 solid particles: class 3s2 boards without coating: chemical g...
Page 136: Applicable Standards
Technical data 136 applicable standards the drive complies with the following standards. The compliance with the european low voltage directive is verified according to standards en 50178, en 61800-5-1 and en 60204-1. • en 50178 (1997) electronic equipment for use in power installations. • en 61800-...
Page 137: Ce Marking
Technical data 137 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). Definitions emc stands for electromagnetic compatibility. It is the ability of electrical/e...
Page 138
Technical data 138 second environment (pds of category c3) the requirements of the emc directive can be met as follows: 1. The drive is equipped with emc filter +e210. The filter is suitable for tn (earthed) and it (unearthed) networks. 2. The motor and control cables are selected as specified in th...
Page 139: “C-Tick” Marking
Technical data 139 “c-tick” marking a “c-tick” mark is attached to each drive in order to verify compliance with the relevant standard (iec 61800-3 (1996) – adjustable speed electrical power drive systems – part 3: emc product standard including specific test methods), mandated by the trans-tasman e...
Page 140
Technical data 140 second environment the drive complies with the limits of iec 61800-3 with the following provisions: 1. It is ensured that no excessive emission is propagated to neighbouring low-voltage networks. In some cases, the natural suppression in transformers and cables is sufficient. If i...
Page 141
Technical data 141.
Page 142
Technical data 142.
Page 143: Dimensions
Dimensions 143 dimensions cabinet line-ups the drive consists of cubicles built into a cabinet line-up. The tables below show the composition of cabinet line-ups for each frame size and the standard combinations of options. The dimensions are in millimetres. Notes: • the side panels increase the tot...
Page 144
Dimensions 144 1×d4 + 2×r8i a u xi liar y contr ol cubicle & supply module cubicle em c /rfi f ilt er cubicle incoming cubicle (with +f253 ) inverter mo dule cubicle joining cu bicle common motor terminal cubicle *b ra ke chopp er 1 *b rak e r esi stor 1 *b ra ke chopp er 2 *b rak e r esi stor 2 *b ...
Page 145
Dimensions 145 2×d4 + 2×r8i a u xi liar y contr ol cubicle incoming cubicle (with +f253 ) incoming cubicle (with +f255 ) s u pply module cubicle inverter mo dule cubicle joining cu bicle common motor terminal cubicle *b ra ke chopp er 1 *b rak e r esi stor 1 *b ra ke chopp er 2 *b rak e r esi stor 2...
Page 146
Dimensions 146 2×d4 + 3×r8i auxiliary control cubicle incoming cubicle (with +f253) incoming cubicle (with +f255) supply module cubicle inverter module cubicle common motor terminal cubicle shipping split widths line-up width net weight (kg approx.) 400 600 800 1800 1800 1350 400 500 600 800 2300 23...
Page 147
Dimensions 147 3×d4 + 5×r8i auxiliary control cubicle incoming cubicle (with +f253) incoming cubicle (with +f255) supply module cubicle inverter module cubicle 1 common motor terminal cubicle inverter module cubicle 2 shipping split widths line-up width net weight (kg approx.) 400 800 800 600 2600 2...
Page 148: Frame Size 1×D4 + 2×R8I
Dimensions 148 frame size 1×d4 + 2×r8i.
Page 149
Dimensions 149 frame size 1×d4 + 2×r8i (continued).
Page 150
Dimensions 150 frame size 1×d4 + 2×r8i (continued).
Page 151
Dimensions 151 frame size 1×d4 + 2×r8i (with a main switch-disconnector +f253).
Page 152
Dimensions 152 frame size 1×d4 + 2×r8i (with +f253) (continued).
Page 153
Dimensions 153 frame size 1×d4 + 2×r8i (with +f253) (continued).
Page 154
Dimensions 154 frame size 1×d4 + 2×r8i (with +f253) (continued).
Page 155
Dimensions 155 frame size 1×d4 + 2×r8i (with +f253) (continued).
Page 156
Dimensions 156 frame size 1×d4 + 2×r8i (with +f253) (continued).
Page 157
Dimensions 157 frame size 1×d4 + 2×r8i (with top entry/exit).
Page 158
Dimensions 158 frame size 1×d4 + 2×r8i (with top entry/exit) (continued).
Page 159
Dimensions 159 frame size 1×d4 + 2×r8i (with top entry/exit) (continued).
Page 160: Frame Size 2×D4 + 2×R8I
Dimensions 160 frame size 2×d4 + 2×r8i.
Page 161
Dimensions 161 frame size 2×d4 + 2×r8i (continued).
Page 162
Dimensions 162 frame size 2×d4 + 2×r8i (continued).
Page 163
Dimensions 163 frame size 2×d4 + 2×r8i (with a main switch-disconnector +f253).
Page 164
Dimensions 164 frame size 2×d4 + 2×r8i (with +f253) (continued).
Page 165
Dimensions 165 frame size 2×d4 + 2×r8i (with +f253) (continued).
Page 166: Frame Size 2×D4 + 3×R8I
Dimensions 166 frame size 2×d4 + 3×r8i.
Page 167
Dimensions 167 frame size 2×d4 + 3×r8i (continued).
Page 168
Dimensions 168 frame size 2×d4 + 3×r8i (continued).
Page 169
Dimensions 169 frame size 2×d4 + 3×r8i (with a main switch-disconnector +f253).
Page 170
Dimensions 170 frame size 2×d4 + 3×r8i (with +f253).
Page 171
Dimensions 171 frame size 2×d4 + 3×r8i (with +f253).
Page 172
Dimensions 172 frame size 2×d4 + 3×r8i (with +f253).
Page 173
Dimensions 173 frame size 2×d4 + 3×r8i (with a main breaker +f255).
Page 174
Dimensions 174 frame size 2×d4 + 3×r8i (with +f255) (continued).
Page 175
Dimensions 175 frame size 2×d4 + 3×r8i (with +f255) (continued).
Page 176
Dimensions 176 frame size 2×d4 + 3×r8i (with +f255) (continued).
Page 177
Dimensions 177 frame size 3×d4 + 4×r8i (with a main switch-disconnector +f253).
Page 178
Dimensions 178 frame size 3×d4 + 4×r8i (with +f253) (continued).
Page 179
Dimensions 179 frame size 3×d4 + 4×r8i (with +f253) (continued).
Page 180
Dimensions 180 frame size 3×d4 + 4×r8i (with +f253) (continued).
Page 181
Dimensions 181 frame size 3×d4 + 4×r8i (with a main breaker +f255).
Page 182
Dimensions 182 frame size 3×d4 + 4×r8i (with +f255) (continued).
Page 183
Dimensions 183 frame size 3×d4 + 4×r8i (with +f255) (continued).
Page 184
Dimensions 184 frame size 3×d4 + 4×r8i (with +f255) (continued).
Page 185
Dimensions 185 common motor terminal cubicle depending on the drive size, the common motor terminal cubicle is either 300, 400 or 600 mm wide. Refer to the cabinet line-up tables at the beginning of this chapter..
Page 186
Dimensions 186 300 mm.
Page 187
Dimensions 187 400 mm.
Page 188
Dimensions 188 600 mm.
Page 189: Resistor Braking
Resistor braking 189 resistor braking what this chapter contains this chapter describes the resistor braking options of the acs800-07 (+v992). Resistor braking options the following acs800-07 (>500 kw) drives are available with brake choppers and resistors. U n acs800-07 (+v992) type brake chopper t...
Page 190
Resistor braking 190 chopper/resistor combinations – technical data the following table contains the technical data of some chopper/resistor combinations. Brake resistors – technical data the following table contains the technical data for the resistors supplied by abb. U n chopper(s) resistors r (o...
Page 191
Resistor braking 191 verifying the capacity of the braking equipment 1. Calculate the maximum power (p max ) generated by the motor during braking. 2. Ensure the following condition is met: the p brmax values specified in the technical data table above are for the reference braking cycle (1 minute o...
Page 192
Resistor braking 192 calculating the maximum braking power (p br ) • braking energy transferred during any ten minute period must be less than or equal to the energy transferred during the reference braking cycle. • the braking power must not exceed the rated maximum value p brmax . Example 1 durati...
Page 193
Resistor braking 193 example 3 duration of a braking cycle is three minutes. The braking time is 10 seconds. Result: the maximum allowed braking power for the cycle is equal to the maximum braking power (p brmax ) given for the reference cycle. T = duration of the braking cycle t br p brmax t p br 6...
Page 194
Resistor braking 194 custom resistor installation and wiring effective cooling of the resistors must be ensured. Warning! All materials near the brake resistors must be non-flammable. The surface temperature of the resistors is high. The temperature of the air rising from the resistors is hundreds o...
Page 195: Brake Circuit Commissioning
Resistor braking 195 the following is a wiring diagram example of the resistor connection. Brake circuit commissioning in the drive application program, overvoltage control of the drive must be disabled for correct operation of the brake chopper. Check the drive parameter setting at the start up. R+...
Page 196
Resistor braking 196.
Page 197
A.
Page 198
B.
Page 199: Further Information
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 200
3aua000 00 689 36 rev a / en effective: 20 10- 03 -1 5 abb oy drives p.O. Box 184 fi-00381 helsinki finland telephone +358 10 22 11 fax +358 10 22 22681 internet www.Abb.Com/drives abb inc. Automation technologies drives & motors 16250 west glendale drive new berlin, wi 53151 usa telephone 262 785-3...