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ABB ACS800 Hardware Manual
Summary of ACS800
Page 1
Acs800 hardware manual acs800-31 drives (5.5 to 110 kw) acs800-u31 drives (7.5 to 125 hp) phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.
Page 2
Acs800 single drive manuals hardware manuals (appropriate manual is included in the delivery) acs800-01/u1 hardware manual 0.55 to 110 kw (0.75 to 150 hp) 3afe64382101 (english) acs800-01/u1 marine supplement 3afe64291275 (english) acs800-02/u2 hardware manual 90 to 500 kw (125 to 600 hp) 3afe645673...
Page 3: Hardware Manual
Acs800-31 drives 5.5 to 110 kw acs800-u31 drives 7.5 to 125 hp hardware manual 3afe68599954 rev a en effective: 14.10.2005 © 2005 abb oy. All rights reserved. Phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.
Page 4
Phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.
Page 5: Update Notice
Update notice 1 update notice new (page 6): safety / installation and maintenance work • after maintaining or modifying a drive safety circuit or changing circuit boards inside the module, retest the functioning of the safety circuit according to the start-up instructions. • do not change the electr...
Page 6
Update notice 2 new (page 31): type code the table below contains the new option code definition for the safe torque off function. New (page 49): emergency stop note: if you add or modify the wiring in the drive safety circuits, ensure that the appropriate standards (e.G. Iec 61800-5-1, en 62061, en...
Page 7
Update notice 3 phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.
Page 8
Update notice 4 warning! The safe torque off function does not disconnect the voltage of the main and auxiliary circuits from the drive. Therefore maintenance work on electrical parts of the drive or the motor can only be carried out after isolating the drive system from the main supply. Note: the s...
Page 9
Update notice 5 see • page 24 for location of terminal block x41 of the drive • page 6 (in this update notice) for the circuit diagram • page 6 (in this update notice) for the dimensions of the asto-11c board • section asto-11c in chapter technical data for the technical data of the asto- 11c board....
Page 10
Update notice 6 circuit diagram the diagram below shows the connection between the asto board and the drive when it is ready. For an example diagram of a complete safe torque off circuit, see page 3 (in this update notice). Dimensions the dimensions of the asto board are the same as the dimensions o...
Page 11
Update notice 7 new (page 111): ambient conditions modules with option +q967: the installation site altitude in operation is 0 to 2000 m. Operation installed for stationary use installation site altitude [...] modules with option +q967 : 0 to 2000 m phone: 800.894.0412 - fax: 888.723.4773 - web: www...
Page 12
Update notice 8 phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.
Page 13: 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 14
Safety instructions 6 installation andmaintenance work these warnings are intended for all who work on the drive, motor cable or motor. Warning! Ignoring the following instructions can cause physical injury or death, or damage to the equipment: • only qualified electricians are allowed to install an...
Page 15
Safety instructions 7 grounding these instructions are intended for all who are responsible for the grounding of the drive. Warning! Ignoring the following instructions can cause physical injury, death, increased electromagnetic interference and equipment malfunction: • ground the drive, motor and a...
Page 16
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 17
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 18
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 19
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 20
Safety instructions 12 phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.
Page 21: Table of Contents
Table of contents 13 table of contents acs800 single drive manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 safety instructions what this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 22
Table of contents 14 type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 mechanical installation unpacking the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 23
Table of contents 15 power factor compensation capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 equipment connected to the motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 installation of s...
Page 24
Table of contents 16 motor control and i/o board (rmio) what this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 to which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 25
Table of contents 17 maintenance what this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 26
Table of contents 18 materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 27: 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 28
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 29
About this manual 21 installation and commissioning flowchart task see identify the frame size of your drive: 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 the motor, ...
Page 30
About this manual 22 inquiries address any inquiries about the product to the local abb representative, quoting the type code and serial number of the unit. If the local abb representative cannot be contacted, address inquiries to the manufacturing facility. Check the insulation of the motor and the...
Page 31: The Acs800-31/u31
The acs800-31/u31 23 the acs800-31/u31 what this chapter contains this chapter describes the operating principle and construction of the drive in short. The acs800-31/u31 the acs800-31/u31 is wall mountable, low-harmonic drive for controlling ac motors. Heat sink control panel cdp312r front cover co...
Page 32
The acs800-31/u31 24 frame size r6 without front and connection box covers location of the line-side converter rmio board location of the motor-side converter rmio board frame size r5 without front and connection box covers pe i/o terminals power cable terminals pe u1 v1 w1 v2 w2 u2 u d c + u d c - ...
Page 33
The acs800-31/u31 25 terms line-side converter: a converter that is connected to the supply network and is capable of transferring energy from the network to the dc link. Motor-side converter: a converter that is connected to the motor and controls the motor operation. Operation principle the line-s...
Page 34
The acs800-31/u31 26 ac voltage and current waveforms the ac line current of the drive is sinusoidal with power factor equal to 1. The igbt supply unit does not generate characteristic current or voltage overtones like a traditional 6- or 12-pulse bridge does. The total harmonic distortion (thd) in ...
Page 35
The acs800-31/u31 27 printed circuit boards the drive contains the following printed circuit boards as standard: • main circuit board (gint) • motor control and i/o board (rmio), 2 pcs • emc filter unit (grfcu) when emc equipment is selected • filter boards (grfc or rrfc) • varistor board (gvar) • c...
Page 36
The acs800-31/u31 28 main circuit and control interfaces diagram app lic ati o n sp ec ifi c p rog ram an d m o to r co ntro l p rogra m rm io bo ard of th e m otor-s ide co nv er te r va ris to r con nec tio n m 3~ lc l f ilt er op tio nal em c fil ter u1 v1 w1 l in e -s ide co nv er te r mo tor-s ...
Page 37
The acs800-31/u31 29 fieldbus control of the line-side converter fieldbus control of the line-side converter can only be performed via the motor-side converter rmio board. The control signal dataset receive and actual signal dataset transmit addresses are shown in section control block diagram below...
Page 38
The acs800-31/u31 30 connection diagram of the rmio board in the line-side converter internal connections to the rmio board for the acs800 igbt supply control program are shown below. Do not change the connections. X20 1 vref- reference voltage -10 vdc, 1 kohm r l 2 gnd x21 1 vref+ reference voltage...
Page 39
The acs800-31/u31 31 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. Acs800-31- 0030-5). The optional selections are given thereafter, separated by plus signs (e.G. +e202). The main se...
Page 40
The acs800-31/u31 32 phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.
Page 41: Mechanical Installation
Mechanical installation 33 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 • residual voltage warning stickers • hardware manual • appropr...
Page 42
Mechanical installation 34 the type designation label is attached to the heat sink and the serial number label to the lower part of the back plate of the unit. Example labels are shown below. Moving the unit lift the unit using the lifting holes at the top and bottom. Type designation label serial n...
Page 43
Mechanical installation 35 before installation the drive must be installed in an upright position with the cooling section facing a wall. Check the installation site according to the requirements below. Refer to chapter dimensional drawings for frame details. Requirements for the installation site s...
Page 44
Mechanical installation 36 mounting the drive on the wall units without vibration dampers 1. Mark the locations for the four holes. The mounting points are shown in chapter dimensional drawings . 2. Fix the screws or bolts to the marked locations. 3. Position the drive onto the screws on the wall. N...
Page 45
Mechanical installation 37 preventing cooling air recirculation prevent air recirculation inside and outside the cabinet. Example hot area main air flow out main air flow in air baffle plates cool area phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.
Page 46
Mechanical installation 38 unit above another lead the out-coming hot cooling air away from the air input of the drive above. Example max.+40°c (+104°f) phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.
Page 47
Planning the electrical installation 39 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 48
Planning the electrical installation 40 3. Check that the motor voltage rating meets the application requirements: see notes 6 and 7 below the requirements table , pages 43 and 44. 4. Consult the motor manufacturer before using a motor in a drive system where the motor nominal voltage differs from t...
Page 49
Planning the electrical installation 41 protecting the motor insulation and bearings the output of the drive comprises – regardless of output frequency – pulses of approximately 1.35 times the equivalent mains network voltage with a very short rise time. This is the case with all drives employing mo...
Page 50
Planning the electrical installation 42 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 51
Planning the electrical installation 43 * 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 52
Planning the electrical installation 44 note 7: drives with an igbt supply unit if voltage is raised by the drive (this is a parameter selectable function), select the motor insulation system according to the increased intermediate circuit dc voltage level, especially in the 500 v supply voltage ran...
Page 53
Planning the electrical installation 45 supply connection disconnecting device (disconnecting means) acs800-01, acs800-u1, acs800-11, acs800-u11, acs800-31, acs800-u31, acs800-02 and acs800-u2 without enclosure extension, acs800-04, acs800-u4 install a hand-operated input disconnecting device (disco...
Page 54
Planning the electrical installation 46 thermal overload and short-circuit protection thermal overload protection the drive protects itself and the input and motor cables against thermal overload when the cables are dimensioned according to the nominal current of the drive. No additional thermal pro...
Page 55
Planning the electrical installation 47 short-circuit protection protect the input cable and drive against short-circuit according to the following guide lines. 1) size the fuses according to local safety regulations, appropriate input voltage and the rated current of the drive (see technical data)....
Page 56
Planning the electrical installation 48 2) circuit breakers which have been tested by abb with the acs800 can be used. Fuses must be used with other circuit breakers. Contact your local abb representative for approved breaker types and supply network characteristics. The protective characteristics o...
Page 57
Planning the electrical installation 49 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 58
Planning the electrical installation 50 prevention of unexpected start the acs800-04, acs800-31/u31 and acs800-07/u7 can be equipped with an optional prevention of unexpected start function according to standards iec/ en 60204-1: 1997; iso/dis 14118: 2000 and en 1037: 1996. The prevention of unexpec...
Page 59
Planning the electrical installation 51 selecting the power cables general rules dimension the mains (input power) and motor cables according to local regulations: • the cable must be able to carry the drive load current. See chapter technical data for the rated currents. • the cable must be rated f...
Page 60
Planning the electrical installation 52 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 61
Planning the electrical installation 53 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 vac cable is accepted for up to...
Page 62
Planning the electrical installation 54 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 63
Planning the electrical installation 55 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 64
Planning the electrical installation 56 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 65
Planning the electrical installation 57 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 66
Planning the electrical installation 58 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 67: Electrical Installation
Electrical installation 59 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 68
Electrical installation 60 it (ungrounded) systems in units with emc filter options (+e202 and +e200 in the type code), disconnect the filter capacitors before connecting the drive to an ungrounded system. Warning! If a drive with emc filter selection +e202 or +e200 is installed on an it system [an ...
Page 69
Electrical installation 61 connecting the power cables diagram input output u1 v1 w1 3 ~ motor u1 v1 w1 1) u2 v2 w2 l1 l2 l3 (pe) (pe) pe 2) 5) 4) 3) drive pe for alternatives, see planning the electrical installation: disconnecting device (disconnecting means) grounding of the motor cable shield at...
Page 70
Electrical installation 62 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 71
Electrical installation 63 2 1 3 views of frame size r5 u1 v1 w1 v2 w2 u2 udc+ udc- 5 5 pe 6 6 8 9 9 phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.
Page 72
Electrical installation 64 frame size r6: screw terminal installation [95 to 185 mm 2 (3/0 to 350 awg)] cables frame sizes 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 a. Connect the cable to the termin...
Page 73
Electrical installation 65 wall installed units (us version) 1. Remove the connection box cover. 2. Remove the front cover by releasing the retaining clip with a screw driver and lifting the cover from the bottom outwards. 3. Remove the gland plate by undoing the fastening screws. 4. Make the cable ...
Page 74
Electrical installation 66 11. Tighten the clamping nuts of the cable glands. After connecting the control cables, fasten the clear plastic shroud and front covers. Warning sticker there are warning stickers in different languages inside the packing box of the drive. Attach a warning sticker in the ...
Page 75
Electrical installation 67 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 76
Electrical installation 68 360 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 77
Electrical installation 69 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 78
Electrical installation 70 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 79: Unexpected Start, +Q950)
Installation of agps board (prevention of unexpected start, +q950) 71 installation of agps board (prevention of unexpected start, +q950) what this chapter contains this chapter describes the electrical installation of the optional prevention of unexpected start function (+q950) of the drive. Prevent...
Page 80
Installation of agps board (prevention of unexpected start, +q950) 72 connect the agps board as follows: • remove the enclosure cover by undoing the fixing screws (1). • ground the bottom plate of the enclosure or via terminal x1:1 of the agps board. • connect the cable delivered with the kit betwee...
Page 81
Installation of agps board (prevention of unexpected start, +q950) 73 circuit diagram this circuit diagram shows how the agps-11 kit is installed. 3afe00374994 drive 115/230 vac n phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.
Page 82
Installation of agps board (prevention of unexpected start, +q950) 74 dimensional drawing the dimensional drawing of the agps board is shown below. 3a f e 682938 98 phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.
Page 83
Motor control and i/o board (rmio) 75 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 application program (factory macro) • specifications of the inputs and outputs of the board. To which produc...
Page 84
Motor control and i/o board (rmio) 76 note on external power supply external +24 v power supply for the rmio board is recommended if • the application requires a fast start after connecting the input power supply • fieldbus communication is required when the input power supply is disconnected. The r...
Page 85
Motor control and i/o board (rmio) 77 external control connections (non-us) external control cable connections to the rmio board for the acs800 standard application program (factory macro) are shown below. For external control connections of other application macros and programs, see the appropriate...
Page 86
Motor control and i/o board (rmio) 78 external control connections (us) external control cable connections to the rmio board for the acs800 standard application program (factory macro us version) are shown below. For external control connections of other application macros and programs, see the appr...
Page 87
Motor control and i/o board (rmio) 79 rmio board specifications analogue inputs with standard application 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 a...
Page 88
Motor control and i/o board (rmio) 80 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 optio...
Page 89
Motor control and i/o board (rmio) 81 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 90
Motor control and i/o board (rmio) 82 phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.
Page 91: Installation Checklist
Installation checklist 83 installation checklist what this chapter contains this chapter contains an installation checklist. Installation checklist check the mechanical and electrical installation of the drive before start-up. Go through the checklist below together with another person. Warning! Onl...
Page 92
Installation checklist 84 the motor connections at u2, v2 and w2 and their tightening torques are ok. The motor cable is routed away from other cables. There are no power factor compensation capacitors in the motor cable. The external control connections inside the drive are ok. There are no tools, ...
Page 93: Start-Up And Use
Start-up and use 85 start-up and use what this chapter contains this chapter describes the start-up procedure and use of the drive. Start-up and use warning! Only qualified electricians are allowed to commission the drive. Read and follow the safety instructions on the first pages of this manual. Ig...
Page 94
Start-up and use 86 control panel the drive is equipped with a control panel (type cdp-312r). The cdp-312r is the user interface of the line-side converter and the motor-side converter of the drive, providing the essential controls such as start/stop/direction/reset/reference, and the parameter sett...
Page 95
Start-up and use 87 to control the motor-side converter... Step action press key display (example) 1. Enter the drive selection mode. 2. Scroll to id number 1. 3. Verify the change to the motor-side converter. Drive acs 800 0050_5lr ixxr7xxx id-number 2 acs 800 0050_5mr acxr7xxx id-number 1 act freq...
Page 96
Start-up and use 88 phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.
Page 97
Actual signals and parameters 89 actual signals and parameters what this chapter contains this chapter contains listings of parameters specific to the acs800-31 and acs800- u31. Line-side converter actual signals and parameters in the motor-side converter application program this section describes t...
Page 98
Actual signals and parameters 90 parameters no. Name/value description fbeq def. 95 hardware specif line converter references and actual signal selections. 95.06 lcu q pow ref reactive power reference for the line converter i.E. The value for par. 24.02 q power ref2 in the igbt supply control progra...
Page 99
Actual signals and parameters 91 acs800-31/u31 specific parameters in the igbt supply control program the signals and parameters of the igbt supply control program which are specific to the acs800-31 and acs800-u31 are described in the tables below. These parameters need not be set in a normal start...
Page 100
Actual signals and parameters 92 31 automatic reset automatic fault reset. Automatic resets are possible only for certain fault types and when the automatic reset function is activated for that fault type. The automatic reset function is not operational if the drive is in local control (l visible on...
Page 101
Actual signals and parameters 93 fixed parameters with the acs800-31 and acs800-u31 when the igbt supply control program is loaded into the acs800-31 or acs800- u31, the following parameters are set to the default values given in the table below. Parameter default value if changed, 11.01 dc ref sele...
Page 102
Actual signals and parameters 94 phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.
Page 103: Maintenance
Maintenance 95 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 104
Maintenance 96 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 105
Maintenance 97 fan replacement (r5, r6) 1. Loosen the fastening screws of the top plate. 2. Push the top plate backwards. 3. Lift the top plate up. 4. Disconnect the fan supply wires (detachable connector). 5. Lift the fan up. 6. Install the new fan in reverse order. Additional fan replacement (r5) ...
Page 106
Maintenance 98 replacement (r6) remove the top cover by lifting it by the rear edge. To remove the fan, release the retaining clips by pulling the back edge (1) of the fan upwards. Disconnect the cable (2, detachable terminal). Install the new fan in reverse order. Capacitors the drive intermediate ...
Page 107: Fault Tracing
Fault tracing 99 fault tracing what this chapter contains this chapter describes the fault tracing of the line-side converter. For motor-side converter fault tracing, see the appropriate application program firmware manual. Faults and warnings displayed by the cdp-312r control panel the control pane...
Page 108
Fault tracing 100 phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.
Page 109: Technical Data
Technical data 101 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. Phone: 800.894.0412 - fax: 888.7...
Page 110
Technical data 102 iec data ratings the iec ratings for the acs800-31 with 50 hz and 60 hz supplies are given below. The symbols are described below the table. Acs800-31 size nominal ratings no- overload use light-overload use heavy-duty use frame size air flow heat dissipation i cont.Max a i max a ...
Page 111
Technical data 103 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 moment...
Page 112
Technical data 104 mains cable fuses fuses for short-circuit protection of the mains cable are listed below. The fuses also protect the adjoining equipment of the drive in case of a short-circuit. Check that the operating time of the fuse is below 0.1 seconds. The operating time depends on the suppl...
Page 113
Technical data 105 cable types the table below gives copper and aluminium cable types for different load currents. Cable sizing is based on max. 9 cables laid on a cable ladder side by side, ambient temperature 30°c, pvc insulation, surface temperature 70°c (en 60204-1 and iec 60364-5-2/2001). For o...
Page 114
Technical data 106 nema data ratings the nema ratings for the acs800-u31 and acs800-31 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 102 . * allowed with motor power ** allowed with motor power symbols no...
Page 115
Technical data 107 input cable fuses the ratings of ul listed fuses for branch circuit protection are listed below. The fuses also prevent damage to the adjoining equipment of the drive in case of a short-circuit inside the drive. Check that the operating time of the fuse is below 0.1 seconds. The o...
Page 116
Technical data 108 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 acco...
Page 117
Technical data 109 input power connection voltage (u 1 ) 208/220/230/240 vac 3-phase± 10% for 230 vac units 380/400/415 vac 3-phase± 10% for 400 vac units 380/400/415/440/460/480/500 vac 3-phase± 10% for 500 vac units 525/550/575/600/660/690 vac 3-phase± 10% for 690 vac units prospective short-circu...
Page 118
Technical data 110 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 = f fwp : frequency at field weakening point; u nmains : mains (input power) voltage; u nmotor : rated motor vol...
Page 119
Technical data 111 ambient conditions environmental limits for the drive are given below. The drive is to be used in a heated, indoor, controlled environment. Operation installed for stationary use storage in the protective package transportation in the protective package installation site altitude ...
Page 120
Technical data 112 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 • extruded aluminium alsi package plywood, bands pp or steel disposal the drive contains raw materials that shou...
Page 121
Technical data 113 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 93/68/eec). Definitions emc stands for electromagnetic...
Page 122
Technical data 114 second environment (drive of category c3) the drive complies with the standard with the following provisions: 1. The drive is equipped with emc filter +e200. See also page 60 . 2. The motor and control cables are selected as specified in the hardware manual. 3. The drive is instal...
Page 123
Technical data 115 “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 124
Technical data 116 second environment (drive of category c3) the drive complies with the standard with the following provisions: 1. The drive is equipped with emc filter +e200. See also page 60 . 2. The motor and control cables are selected as specified in the hardware manual. 3. The drive is instal...
Page 125
Technical data 117 ul/csa markings the acs800-u31 and acs800-31 are c-ul us listed. Csa marking is pending. Ul the drive is suitable for use on a circuit capable of delivering not more than 65 ka rms symmetrical amperes at the drive nominal voltage (600 v maximum for 690 v units) when protected by t...
Page 126
Technical data 118 phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.
Page 127: Dimensional Drawings
Dimensional drawings 119 dimensional drawings the dimensions are given in millimetres and [inches]. Phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.
Page 128
Dimensional drawings 120 frame size r5 (ip21, ul type open, ul type 1) 6 840 62 00 a us gla nd/c ondu it pl ate d iam et ers of k no ck -ou t ho les : 50 mm [1 .97 in. ], 22 .7 mm [.8 9 in .]. T he uni t is ul typ e 1 w hen eq uip ped w ith th e u s gl and pl ate. Phone: 800.894.0412 - fax: 888.723....
Page 129
Dimensional drawings 121 frame size r6 (ip21, ul type open, ul type 1) 6 840 572 6 a u s glan d/co ndui t plate d iam ete rs o f k noc k- out hol es : 63 .5 m m [2.5 0 in.], 22.7 m m [.89 in .]. Th e u n it is u l ty pe 1 w h en equ ipp ed w ith the u s g lan d p lat e . Phone: 800.894.0412 - fax: 8...
Page 130
Dimensional drawings 122 phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.
Page 131: Resistor Braking
Resistor braking 123 resistor braking what this chapter contains this chapter describes how to select, protect and wire external brake choppers and resistors for the drive. The chapter also contains installation instructions and the technical data. How to select the correct drive/chopper/resistor co...
Page 132
Resistor braking 124 external brake chopper and resistor(s) for the acs800-31/u31 the nominal ratings for dimensioning the brake resistors for the acs800-31 and acs800-u31 are given below at an ambient temperature of 40°c (104°f). R resistance value for the listed resistor assembly. Note: this is al...
Page 133
Resistor braking 125 brake chopper and resistor installation the installation instructions for the chopper and resistor are given in nbra-6xx braking choppers installation and start-up guide [3afy58920541 (english)]. All choppers and resistors must be installed outside the drive module in a place wh...
Page 134
Resistor braking 126 brake circuit commissioning for standard application program: • switch off the overvoltage control of the drive (parameter 20.05). • frame size r6: check the setting of parameter 21.09. If stop by coasting is required, select off2 stop. For the use of the brake resistor overload...
Page 135: Via Terminal X34
External +24 v power supply for the rmio boards via terminal x34 127 external +24 v power supply for the rmio boards via terminal x34 what this chapter contains this chapter describes how to connect an external +24 v power supply for the rmio boards of the motor-side and line-side converters via ter...
Page 136
External +24 v power supply for the rmio boards via terminal x34 128 connecting +24 v external power supply rmio board of the motor-side converter 1. Break off the tab covering the +24 vdc power input connector with pliers. 2. Pull the connector outwards. 3. Disconnect the wires from the connector (...
Page 137
External +24 v power supply for the rmio boards via terminal x34 129 8 1 2 + - rmio board x34 1 2 3 + - rmio board x34 7 connection of a two-way connector 1 2 3 1 2 3 connection of a three-way connector phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.
Page 138
External +24 v power supply for the rmio boards via terminal x34 130 rmio board of the line-side converter frame size r5 the location of terminal x34 in the line-side converter is shown below. Connect the external +24 v supply to the board as described in steps 2 to 8 in section rmio board of the mo...
Page 139
External +24 v power supply for the rmio boards via terminal x34 131 9. Lift the upper plastic cover off. 10. Connect the external +24 v supply to the board as described in steps 2 to 5, 7 and 8 in section rmio board of the motor-side converter . 11. Reconnect all disconnected cables and fasten the ...