1. DL manuals
  2. ABB
  3. Servo Drives
  4. ACS800
  5. Hardware Manual

ABB ACS800 Hardware Manual

Manual is about: ACS800-07 (+V992) drives (500 to 2800 kW)

Summary of ACS800

  • Page 1

    Acs800 hardware manual acs800-01 drives (0.55 to 200 kw) acs800-u1 drives (0.75 to 200 hp) 800_01_hw.Book page 1 friday, october 3, 2008 9:51 am.

  • Page 2

    Acs800 single drive manuals hardware manuals (appropriate manual is included in the delivery) acs800-01/u1 hardware manual 0.55 to 200 kw (0.75 to 200 hp) 3afe64382101 (english) acs800-01/u1/04 marine supplement 0.55 to 160 kw (0.75 to 200 hp) 3afe68291275 (english) acs800-11/u11 hardware manual 5.5...

  • Page 3

    Acs800-01 drives 0.55 to 200 kw acs800-u1 drives 0.75 to 200 hp hardware manual 3afe64382101 rev j en effective: 1.10.2008 © 2008 abb oy. All rights reserved. 800_01_hw.Book page 3 friday, october 3, 2008 9:51 am.

  • Page 4

    800_01_hw.Book page 4 friday, october 3, 2008 9:51 am.

  • 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 and maintenance 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 a...

  • 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

    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

    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 12 800_01_hw.Book page 12 friday, october 3, 2008 9:51 am.

  • 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 delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 15

    Table of contents 15 selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 ...

  • Page 16

    Table of contents 16 what this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73 note on terminal labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 17

    Table of contents 17 fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 frame sizes r2 to r4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 frame sizes ...

  • Page 18

    Table of contents 18 frame size r2 (ip 21, ul type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118 frame size r2 (ip 55, ul type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119 frame si...

  • 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 this 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 ...

  • Page 20

    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 lists the steps in checking the delivery and installing and commissioning...

  • Page 21

    About this manual 21 installation and commissioning flowchart task see identify the frame size of your drive: r2, r3, r4, r5 or r6. Technical data / iec data or nema data plan the installation. Check the ambient conditions, ratings, required cooling air flow, input power connection, compatibility of...

  • Page 22

    About this manual 22 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 23: The Acs800-01/u1

    The acs800-01/u1 23 the acs800-01/u1 what this chapter contains this chapter describes the operating principle and construction of the drive in short. The acs800-01/u1 the acs800-01/u1 is a wall mountable drive for controlling ac motors. Connection box control panel cdp312r heat sink front cover ip ...

  • Page 24

    The acs800-01/u1 24 type code the type code contains information on the specifications and configuration of the drive. The first digits from left express the basic configuration (e.G. Acs800-01- 0006-5). The optional selections are given thereafter, separated by + signs (e.G. +e202). The main select...

  • Page 25

    The acs800-01/u1 25 main circuit and control diagram this diagram shows the control interfaces and the main circuit of the drive. 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 cap...

  • Page 26

    The acs800-01/u1 26 printed circuit boards the drive contains the following printed circuit boards as standard: • main circuit board (rint) • motor control and i/o board (rmio) • emc filter board (rrfc) when emc equipment is selected or varistor board (rvar) otherwise • control panel (cdp 312r). Mot...

  • Page 27: Mechanical Installation

    Mechanical installation 27 mechanical installation unpacking the unit the drive is delivered in a box that also contains: • plastic bag containing: screws (m3), clamps and cable lugs (2 mm 2 , m3) for grounding the control cable screens • connection box (screws, clamps and vibration dampers with +c1...

  • Page 28

    Mechanical installation 28 delivery check check that there are no signs of damage. Before attempting installation and operation, check the information on the type designation label of the drive to verify that the unit is of the correct type. The label includes an iec and nema rating, ul, c-ul, csa a...

  • Page 29

    Mechanical installation 29 free space around the unit required free space around the drive to enable cooling air flow, service and maintenance is shown below in millimetres and [inches]. When mounting ip 55 units above one another, leave 200 mm (7.9 in.) free space above and below the unit. Ip 21 (u...

  • Page 30

    Mechanical installation 30 mounting the drive on the wall units without vibration dampers 1. Mark the locations for the four holes. The mounting points are shown in dimensional drawings . In frame sizes r2 to r5 (ip 21, ul type 1), use the mounting template cut from the package. 2. Fix the screws or...

  • Page 31

    Mechanical installation 31 cabinet installation for better cooling, it is recommended to remove the front cover if the unit is installed into a cabinet. The required distance between parallel units is five millimetres (0.2 in.) in installations without the front cover. The cooling air entering the u...

  • Page 32

    Mechanical installation 32 unit above another lead the out-coming cooling air away from the unit above. Example max.+40 °c (+104 °f) 800_01_hw.Book page 32 friday, october 3, 2008 9:51 am.

  • Page 33

    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 example 1: when the supply voltage is 440 v and a drive with a diode supply is operating in motor mode only, the maximum peak voltage in the motor terminals can be approximated as follows: 440 v · 1.35 · 2 = 1190 v. Check that the motor insulation system withs...

  • Page 35

    Planning the electrical installation 35 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 36

    Planning the electrical installation 36 * 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 37

    Planning the electrical installation 37 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 38

    Planning the electrical installation 38 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 39

    Planning the electrical installation 39 supply connection disconnecting device (disconnecting means) install a hand-operated input disconnecting device (disconnecting means) between the ac power source and the drive. The disconnecting device must be of a type that can be locked to the open position ...

  • Page 40

    Planning the electrical installation 40 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 41

    Planning the electrical installation 41 protection against short-circuit inside the drive or in the supply cable protect the drive and input cable with fuses or a circuit breaker. Fuses size the fuses according to instructions given in chapter technical data. The fuses will protect the input cable i...

  • Page 42

    Planning the electrical installation 42 ground fault protection the drive is equipped with an internal ground fault protective function to protect the unit against ground faults in the motor and motor cable. This is not a personal safety or a fire protection feature. The ground fault protective func...

  • Page 43

    Planning the electrical installation 43 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 ...

  • Page 44

    Planning the electrical installation 44 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 45

    Planning the electrical installation 45 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 46

    Planning the electrical installation 46 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 47

    Planning the electrical installation 47 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 48

    Planning the electrical installation 48 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 49

    Planning the electrical installation 49 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 50

    Planning the electrical installation 50 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 51: Electrical Installation

    Electrical installation 51 electrical installation what this chapter contains this chapter describes the electrical installation procedure of the drive. Warning! The work described in this chapter may only be carried out by a qualified electrician. Follow the safety instructions on the first pages o...

  • Page 52

    Electrical installation 52 checking the insulation of the assembly drive every drive has been tested for insulation between the main circuit and the chassis (2500 v rms 50 hz for 1 second) at the factory. Therefore, do not make any voltage tolerance or insulation resistance tests (e.G. Hi-pot or meg...

  • Page 53

    Electrical installation 53 connecting the power cables diagram input output u1 v1 w1 3 ~ motor u1 v1 w1 1) u2 v2 w2 udc+ r+ udc - r - l1 l2 l3 (pe) (pe) pe 2) 5) 4) 4) 3) drive pe for alternatives, see planning the electrical installation: disconnecting device (disconnecting means) external brake re...

  • Page 54

    Electrical installation 54 conductor stripping lengths strip the conductor ends as follows to fit them inside the power cable connection terminals. Allowed wire sizes, tightening torques see technical data : cable entries . Wall installed units (european version) power cable installation procedure 1...

  • Page 55

    Electrical installation 55 fasten the control cables between these plates with cable ties motor cable u2 v2 w2 u1 v1 w1 5 5 input power cable udc+ r - r+ udc - pe 6 6 frame sizes r2 to r4 1 3 3 2 4 8 fastening screws fastening hooks cover bottom plate grommet 360 degrees grounding clamp control cabl...

  • Page 56

    Electrical installation 56 frame size r5 6 5 5 6 8 8 u1 v1 w1 v2 w2 u2 r- udc+ r+ udc- 6 3 3 800_01_hw.Book page 56 friday, october 3, 2008 9:51 am.

  • Page 57

    Electrical installation 57 frame size r6: cable terminal installation [95 to 240 mm 2 (3/0 to 500 mcm)] cables frame size r6: cable lug installation [16 to 70 mm 2 (6 to 2/0 awg) cables] isolate the ends of the cable lugs with insulating tape or shrink tubing. 5 5 pe 3 3 a. Connect the cable to the ...

  • Page 58

    Electrical installation 58 wall installed units (us version) 1. Remove the front cover (in frame size r6 the lower front cover) by releasing the retaining clip with a screw driver and lifting the cover from the bottom outwards. 2. Make the cable entry holes in the gland box by breaking off the suita...

  • Page 59

    Electrical installation 59 8. Tighten the clamping nuts of the cable glands. After connecting the control cables, fasten the front covers. Warning sticker there are warning stickers in different languages inside the packing box of the drive. Attach a warning sticker in the language of your choice on...

  • Page 60

    Electrical installation 60 protect the rmio board terminals x25 to x27 against contact when input voltage exceeds 50 v ac. Frame size r5 cover the power cable terminals as follows: 1. Cut holes for the installed cables into the clear plastic shroud. 2. Press the shroud onto the terminals. Removal of...

  • Page 61

    Electrical installation 61 frame size r6 cover the power cable terminals as follows: 1. Cut holes for the installed cables into the clear plastic shroud in cable lug installations. 2. Press the shroud onto the terminals. Removal of the shroud by lifting up with a screw driver from the corner: 2 1 vi...

  • Page 62

    Electrical installation 62 connecting the control cables lead the cable through the control cable entry (1). Connect the control cables as described below. Connect the conductors to the appropriate detachable terminals of the rmio board [refer to chapter motor control and i/o board (rmio) ]. Tighten...

  • Page 63

    Electrical installation 63 frame sizes r5 and r6 detachable connection terminals (pull up) optional module 1 optional module 2 control panel place the warning sticker here control cable grounding: see section 360 degrees grounding ddcs communication option module 3: rdco view of frame size r6 termin...

  • Page 64

    Electrical installation 64 360 degrees grounding when the outer surface of the shield is covered with non-conductive material • strip the cable carefully (do not cut the grounding wire and the shield) • turn the shield inside out to expose the conductive surface. • wrap the grounding wire around the...

  • Page 65

    Electrical installation 65 cabling of i/o and fieldbus modules pulse encoder module cabling shield module 2 3 4 1 as short as possible note: the rdio module does not include a terminal for cable shield grounding. Ground the pair cable shields here. Shield rtac 2 3 4 1 wrap copper tape around the str...

  • Page 66

    Electrical installation 66 fastening the control cables and covers when all control cables are connected, fasten them together with cable ties. Units with a connection box: fasten the cables to the entry plate with cable ties. Units with a gland box: tighten the clamping nuts of the cable glands. Fa...

  • Page 67: Unexpected Start, +Q950)

    Installation of agps board (prevention of unexpected start, +q950) 67 installation of agps board (prevention of unexpected start, +q950) what this chapter contains this chapter describes • electrical installation of the optional prevention of unexpected start function (+q950) of the drive. • specifi...

  • Page 68

    Installation of agps board (prevention of unexpected start, +q950) 68 connect the agps board as follows: • remove the enclosure cover by undoing the fixing screws (1). • ground the unit via the bottom plate of the enclosure or via terminal x1:1 of the agps board. • connect the cable delivered with t...

  • Page 69

    Installation of agps board (prevention of unexpected start, +q950) 69 circuit diagram this circuit diagram shows how the agps-11 kit is installed. 3 a fe 00 37 499 4 800_01_hw.Book page 69 friday, october 3, 2008 9:51 am.

  • Page 70

    Installation of agps board (prevention of unexpected start, +q950) 70 dimensional drawing the dimensional drawing of the agps board is shown below. $)( 800_01_hw.Book page 70 friday, october 3, 2008 9:51 am.

  • Page 71

    Installation of agps board (prevention of unexpected start, +q950) 71 agps-11c board specifications nominal input voltage 115...230 v ac ±10% nominal input current 0.1 a (230 v) / 0.2 a (115 v) nominal frequency 50/60 hz max. External fuse 16 a x1 terminal sizes 3 x 2.5 mm 2 output voltage 15 v dc ±...

  • Page 72

    Installation of agps board (prevention of unexpected start, +q950) 72 800_01_hw.Book page 72 friday, october 3, 2008 9:51 am.

  • Page 73

    Motor control and i/o board (rmio) 73 motor control and i/o board (rmio) what this chapter contains this chapter shows • external control connections to the rmio board for the acs800 standard control program (factory macro) • specifications of the inputs and outputs of the board. Note on terminal la...

  • Page 74

    Motor control and i/o board (rmio) 74 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 75

    Motor control and i/o board (rmio) 75 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 76

    Motor control and i/o board (rmio) 76 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 77

    Motor control and i/o board (rmio) 77 relay outputs three programmable relay outputs switching capacity 8 a at 24 v dc or 250 v ac, 0.4 a at 120 v dc minimum continuous current 5 ma rms at 24 v dc maximum continuous current 2 a rms insulation test voltage 4 kv ac, 1 minute ddcs fibre optic link with...

  • Page 78

    Motor control and i/o board (rmio) 78 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 79: Installation Checklist

    Installation checklist 79 installation checklist checklist check the mechanical and electrical installation of the drive before start-up. Go through the checklist below together with another person. Read the safety instructions on the first pages of this manual before you work on the unit. Check mec...

  • Page 80

    Installation checklist 80 800_01_hw.Book page 80 friday, october 3, 2008 9:51 am.

  • Page 81: Maintenance

    Maintenance 81 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 82

    Maintenance 82 heatsink the heatsink fins pick up dust from the cooling air. The drive runs into overtemperature warnings and faults if the heatsink is not clean. In a “normal” environment (not dusty, not clean) the heatsink should be checked annually, in a dusty environment more often. Clean the he...

  • Page 83

    Maintenance 83 fan replacement (r4) 1. Loosen the screws that fasten the fan mounting plate to the frame. 2. Push the fan mounting plate to the left and pull it out. 3. Disconnect the fan power cable. 4. Undo the screws that fasten the fan to the fan mounting plate. 5. Install the new fan in reverse...

  • Page 84

    Maintenance 84 fan replacement (r5) 1. Undo the fastening screws of the swing-out frame. 2. Open the swing-out frame. 3. Disconnect the cable. 4. Undo the fastening screws of the fan. 5. Install the new fan in reverse order. Bottom view 1 1 3 2 4 4 800_01_hw.Book page 84 friday, october 3, 2008 9:51...

  • Page 85

    Maintenance 85 fan replacement (r6) to remove the fan, undo the fixing screws. Disconnect the cable. Install the new fan in reverse order. Note: in -0205-3 and 0255-5 units, access the fan through the opening in the support frame when changing the fan. Additional fan there is an additional cooling f...

  • Page 86

    Maintenance 86 replacement (r4, r5) remove the front cover. The fan is located on the lower right-hand side of the unit (r4) or on the right-hand side of the control panel (r5). Lift the fan out and disconnect the cable. Install the fan in reverse order. Replacement (r6) remove the top cover by lift...

  • Page 87

    Maintenance 87 leds this table describes leds of the drive. * the leds are not visible in frame sizes r2 to r6. 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 (with type code selection +0j400 only) red dr...

  • Page 88

    Maintenance 88 800_01_hw.Book page 88 friday, october 3, 2008 9:51 am.

  • Page 89: Technical Data

    Technical data 89 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 90

    Technical data 90 three-phase supply voltage 380 v, 400 v or 415 v -0003-3 5.1 6.5 1.5 4.7 1.5 3.4 1.1 r2 35 100 -0004-3 6.5 8.2 2.2 5.9 2.2 4.3 1.5 r2 35 120 -0005-3 8.5 10.8 3 7.7 3 5.7 2.2 r2 35 140 -0006-3 10.9 13.8 4 10.2 4 7.5 3 r2 35 160 -0009-3 13.9 17.6 5.5 12.7 5.5 9.3 4 r2 35 200 -0011-3 ...

  • Page 91

    Technical data 91 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 ...

  • Page 92

    Technical data 92 derating the load capacity (current and power) decreases if the installation site altitude exceeds 1000 metres (3300 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 output curren...

  • Page 93

    Technical data 93 three-phase supply voltage 380 v, 400 v or 415 v -0003-3 4.7 10 483 500 abb control ofaf000h10 000 -0004-3 6.0 10 483 500 abb control ofaf000h10 000 -0005-3 7.9 10 483 500 abb control ofaf000h10 000 -0006-3 10 16 993 500 abb control ofaf000h16 000 -0009-3 13 16 993 500 abb control ...

  • Page 94

    Technical data 94 frame sizes r5 and r6 choose between gg and ar fuses according to the table under quick guide for selecting between gg and ar fuses on page 99 , or verify the operating time by checking that the short-circuit current of the installation is at least the value given in the fuse table...

  • Page 95

    Technical data 95 the calculated short-circuit current 2.7 ka is higher than the minimum short-circuit current of the drive gg fuse type ofaf00h160 (2400 a). -> the 500 v gg fuse (abb control ofaf00h160) can be used. = 410 v 2 · (67.66 mohm) 2 + (22.19 mohm + 13.94 mohm) 2 i k2-ph = 2.7 ka 800_01_hw...

  • Page 96

    Technical data 96 fuse tables for frame sizes r5 and r6 standard gg fuses acs800-01 size input current min. Short- circuit current 1) fuse a a a 2 s * v manufacturer type iec size three-phase supply voltage 208 v, 220 v, 230 v or 240 v -0025-2 67 1050 80 34500 500 abb control ofaf000h80 000 -0030-2 ...

  • Page 97

    Technical data 97 * maximum total i 2 t value for 550 v or 690 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 102 . Note 2: in multicable ins...

  • Page 98

    Technical data 98 -0060-7 58 400 100 4650 690 bussmann 170m1567 000 -0070-7 79 520 125 8500 690 bussmann 170m1568 000 -0100-7 91 695 160 16000 690 bussmann 170m1569 000 -0120-7 112 750 200 15000 690 bussmann 170m3815 1* -0145-7 131 1520 350 68500 690 bussmann 170m3818 din1* -0175-7 162 1520 350 6850...

  • Page 99

    Technical data 99 quick guide for selecting between gg and ar fuses the table below is a short cut in selecting between gg and ar fuses. The combinations (cable size, cable length, transformer size and fuse type) in the table fulfil the minimum requirements for the proper operation of the fuse. Acs8...

  • Page 100

    Technical data 100 the following parameters may effect on correct the operation of the protection: • cable length, i.E. The longer the cable the weaker the fuse protection, as the long cable limits the fault current • cable size, i.E. The smaller the cable the weaker the fuse protection, as the smal...

  • Page 101

    Technical data 101 cable entries brake resistor, mains and motor cable terminal sizes (per phase), accepted cable diameters and tightening torques are given below . * 16 mm 2 rigid solid cable, 10 mm 2 flexible stranded cable ** with cable lugs 16...70 mm 2 , tightening torque 20...40 nm. Cable lugs...

  • Page 102

    Technical data 102 nema data ratings the nema ratings for the acs800-u1 with 60 hz supplies are given below. The symbols are described below the table. For sizing, derating and 50 hz supplies, see iec data on page 89 . Acs800-u1 size i max normal use heavy-duty use frame size air flow heat dissipati...

  • Page 103

    Technical data 103 * overload may be limited to 5% at high speeds (> 90% speed) by the internal power limit of the drive. The limitation also depends on motor characteristics and network voltage. ** overload may be limited to 40% at high speeds (> 90% speed) by the internal power limit of the drive....

  • Page 104

    Technical data 104 fuses ul class t fuses fuses for branch circuit protection are listed below. Fast acting class t or faster fuses are recommended in the usa. Check from the fuse time-current curve that the operating time of the fuse is below 0.5 seconds for units of frame sizes r2 to r4 and 0.1 se...

  • Page 105

    Technical data 105 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...

  • Page 106

    Technical data 106 cable entries brake resistor, input and motor cable (per phase) terminal sizes, accepted cable diameters and tightening torques are given below . * 6 awg rigid solid cable, 8 awg flexible stranded cable ** with cable lugs 6...2/0 awg, tightening torque 14.8...29.5 lbf ft. Cable lu...

  • Page 107

    Technical data 107 input power connection voltage ( u 1 ) 208/220/230/240 v ac 3-phase ± 10% for 230 v ac units 380/400/415 v ac 3-phase ± 10% for 400 v ac units 380/400/415/440/460/480/500 v ac 3-phase ± 10% for 500 v ac units 525/550/575/600/660/690 v ac 3-phase ± 10% for 690 v ac units short-circ...

  • Page 108

    Technical data 108 cooling method internal fan, flow direction from bottom to top. Free space around the unit see chapter mechanical installation . Degrees of protection ip 21 (ul type 1) and ip 55 (ul type 12). Without connection box and front cover, the unit must be protected against contact accor...

  • Page 109

    Technical data 109 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 mm, thickness of coating 100 micrometres • cast aluminium alsi (r2 and r3) • extruded aluminium alsi (r4 to r6) package corrugated cardboard (ip 21 units...

  • Page 110

    Technical data 110 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 e lectro m agn...

  • Page 111

    Technical data 111 second environment (drive of category c3) the drive complies with the standard with the following provisions: 1. Frame sizes r2…r5: the drive is equipped with emc filter +e200. The filter is suitable for tn (earthed) systems only. Frame size r6: the drive is equipped with emc filt...

  • Page 112

    Technical data 112 “c-tick” marking “c-tick” marking is required in australia and new zealand. A “c-tick” mark is attached to each drive in order to verify compliance with the relevant standard (iec 61800-3 (2004) – adjustable speed electrical power drive systems. Part 3: emc requirements and specif...

  • Page 113

    Technical data 113 second environment (drive of category c3) the drive complies with the standard with the following provisions: 1. Frame sizes r2…r5: the drive is equipped with emc filter +e200. The filter is suitable for tn (earthed) systems only. Frame size r6: the drive is equipped with emc filt...

  • Page 114

    Technical data 114 ul/csa markings the acs800-01 and acs800-u1 units of ul type 1 are c-ul us listed and csa marked. 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 voltage (600 v maximum for 690 v units) when prot...

  • Page 115

    Technical data 115 if you have any questions concerning your abb drive, please contact the local distributor or abb office. The technical data, information and specifications are valid at the time of printing. The manufacturer reserves the right to modifications without prior notice. 800_01_hw.Book ...

  • Page 116

    Technical data 116 800_01_hw.Book page 116 friday, october 3, 2008 9:51 am.

  • Page 117: Dimensional Drawings

    Dimensional drawings 117 dimensional drawings dimensional drawings of the acs800-01 are shown below. The dimensions are given in milllimetres and [inches]. 800_01_hw.Book page 117 friday, october 3, 2008 9:51 am.

  • Page 118

    Dimensional drawings 118 frame size r2 (ip 21, ul type 1) 646461 17-b 800_01_hw.Book page 118 friday, october 3, 2008 9:51 am.

  • Page 119

    Dimensional drawings 119 frame size r2 (ip 55, ul type 12) 64646150-b 800_01_hw.Book page 119 friday, october 3, 2008 9:51 am.

  • Page 120

    Dimensional drawings 120 frame size r3 (ip 21, ul type 1) 64646192- b 800_01_hw.Book page 120 friday, october 3, 2008 9:51 am.

  • Page 121

    Dimensional drawings 121 frame size r3 (ip 55, ul type 12) 64646206- c 800_01_hw.Book page 121 friday, october 3, 2008 9:51 am.

  • Page 122

    Dimensional drawings 122 frame size r4 (ip 21, ul type 1) 64646214-b 800_01_hw.Book page 122 friday, october 3, 2008 9:51 am.

  • Page 123

    Dimensional drawings 123 frame size r4 (ip 55, ul type 12) 64647130- b 800_01_hw.Book page 123 friday, october 3, 2008 9:51 am.

  • Page 124

    Dimensional drawings 124 frame size r5 (ip 21, ul type 1) 64646222- b 800_01_hw.Book page 124 friday, october 3, 2008 9:51 am.

  • Page 125

    Dimensional drawings 125 frame size r5 (ip 55, ul type 12) 64647156-b 800_01_hw.Book page 125 friday, october 3, 2008 9:51 am.

  • Page 126

    Dimensional drawings 126 frame size r6 (ip 21, ul type 1) 64646231-b 800_01_hw.Book page 126 friday, october 3, 2008 9:51 am.

  • Page 127

    Dimensional drawings 127 frame size r6 (ip 21, ul type 1), -205-3 and -255-5 units note: only measurements that differ from those of the standard frame size r6 (ip 21, ul type 1) are given below. 3aua0000045356 800_01_hw.Book page 127 friday, october 3, 2008 9:51 am.

  • Page 128

    Dimensional drawings 128 frame size r6 (ip 55, ul type 12) 64684957-c 800_01_hw.Book page 128 friday, october 3, 2008 9:51 am.

  • Page 129

    Supplementary page 3aua0000057717 2009-04-16 a frame size r6 (ip 55, ul type 12) -0205-3 and -0255-5 units 3a u a 0000057578-a.

  • Page 130

    Dimensional drawings 129 dimensional drawings (usa) dimensional drawings of the acs800-u1 are shown below. The dimensions are given in milllimetres and [inches]. 800_01_hw.Book page 129 friday, october 3, 2008 9:51 am.

  • Page 131

    Dimensional drawings 130 frame size r2 (ul type 1, ip 21) 64741829-a 800_01_hw.Book page 130 friday, october 3, 2008 9:51 am.

  • Page 132

    Dimensional drawings 131 frame size r2 (ul type 12, ip 55) 64788051- a 800_01_hw.Book page 131 friday, october 3, 2008 9:51 am.

  • Page 133

    Dimensional drawings 132 frame size r3 (ul type 1, ip 21) 64 74181 1-a 800_01_hw.Book page 132 friday, october 3, 2008 9:51 am.

  • Page 134

    Dimensional drawings 133 frame size r3 (ul type 12, ip 55) 64 788078-a 800_01_hw.Book page 133 friday, october 3, 2008 9:51 am.

  • Page 135

    Dimensional drawings 134 frame size r4 (ul type 1, ip 21) 64741802- a 800_01_hw.Book page 134 friday, october 3, 2008 9:51 am.

  • Page 136

    Dimensional drawings 135 frame size r4 (ul type 12, ip 55) 64788086-a 800_01_hw.Book page 135 friday, october 3, 2008 9:51 am.

  • Page 137

    Dimensional drawings 136 frame size r5 (ul type 1, ip 21) 64741748-a 800_01_hw.Book page 136 friday, october 3, 2008 9:51 am.

  • Page 138

    Dimensional drawings 137 frame size r5 (ul type 12, ip 55) 64788094-a 800_01_hw.Book page 137 friday, october 3, 2008 9:51 am.

  • Page 139

    Dimensional drawings 138 frame size r6 (ul type 1, ip 21) 64739361-a 800_01_hw.Book page 138 friday, october 3, 2008 9:51 am.

  • Page 140

    Dimensional drawings 139 frame size r6 (ul type 1, ip 21) -0205-3 and -0255-5 units note: only measurements that differ from those of the standard frame size r6 (ul type 1, ip 21) are given below. 3a u a 0000045584 800_01_hw.Book page 139 friday, october 3, 2008 9:51 am.

  • Page 141

    Dimensional drawings 140 frame size r6 (ul type 12, ip 55) 64788108-a 800_01_hw.Book page 140 friday, october 3, 2008 9:51 am.

  • Page 142

    Supplementary page 3aua0000057717 2009-04-16 b frame size r6 (ul type 12, ip 55) -0205-3 and -0255-5 units 3aua0000057583- a.

  • Page 143: Resistor Braking

    Resistor braking 141 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. Availability of brake choppers and resistors for the acs800 frame r2 and r3 drives and 690 v units of fr...

  • Page 144

    Resistor braking 142 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 145

    Resistor braking 143 400 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 146

    Resistor braking 144 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 147

    Resistor braking 145 protection of frame sizes r2 to r5 (acs800-01/u1) it is highly recommended to equip the drive with a main contactor for safety reasons. Wire the contactor so that it opens in case the resistor overheats. This is essential for safety since the drive will not otherwise be able to ...

  • Page 148

    Resistor braking 146 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 149: Terminal X34

    External +24 v power supply for the rmio board via terminal x34 147 external +24 v power supply for the rmio board via terminal x34 what this chapter contains this chapter describes how to connect an external +24 v power supply for the rmio board via terminal x34. For the current consumption of the ...

  • Page 150

    External +24 v power supply for the rmio board via terminal x34 148 connecting +24 v external power supply 1. Break off the tab covering the +24 vdc power input connector with pliers. 2. Lift the connector upwards. 3. Disconnect the wires from the connector (keep the connector for later use). 4. Iso...

  • Page 151

    External +24 v power supply for the rmio board via terminal x34 149 5 6 7 8 1 2 + - rmio board x34 1 2 3 + - rmio board x34 connection of a two-way connector 1 2 3 1 2 3 connection of a three-way connector 800_01_hw.Book page 149 friday, october 3, 2008 9:51 am.

  • Page 152

    External +24 v power supply for the rmio board via terminal x34 150 800_01_hw.Book page 150 friday, october 3, 2008 9:51 am.

  • Page 153

    800_01_hw.Book page 151 friday, october 3, 2008 9:51 am.

  • Page 154

    3afe643 8210 1 rev j en eff e ctive: 1.10 .200 8 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 800-he...