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ABB ACS800 Hardware Manual

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

Summary of ACS800

  • Page 1

    Acs800 hardware manual acs800-02 drives (45 to 560 kw) acs800-u2 drives (60 to 600 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 160 kw (0.75 to 200 hp) 3afe64382101 (english) acs800-01/u1/04 marine supplement 0.55 to 160 kw (0.75 to 200 hp) 3afe64291275 (english) acs800-11/u11 hardware manual 5.5...

  • Page 3: Hardware Manual

    Acs800-02 drives 45 to 560 kw acs800-u2 drives 60 to 600 hp hardware manual 3afe64567373 rev f en effective: 15.8.2007 © 2007 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: Safety Instructions

    Safety instructions 5 safety instructions what this chapter contains this chapter contains the safety instructions which you must follow when installing, operating and servicing the drive. If ignored, physical injury or death may follow, or damage may occur to the drive, motor or driven equipment. R...

  • Page 6

    Safety instructions 6 installation andmaintenance work these warnings are intended for all who work on the drive, motor cable or motor. Warning! Ignoring the following instructions can cause physical injury or death, or damage to the equipment: • only qualified electricians are allowed to install an...

  • Page 7

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

  • Page 8

    Safety instructions 8 mechanical installation and maintenance these instructions are intended for all who install and service the drive. Warning! Ignoring the following instructions can cause physical injury or death, or damage to the equipment: • handle the unit carefully. • acs800-01, acs800-11, a...

  • Page 9

    Safety instructions 9 printed circuit boards fibre optic cables warning! Ignoring the following instructions can cause damage to the printed circuit boards: • the printed circuit boards contain components sensitive to electrostatic discharge. Wear a grounding wrist band when handling the boards. Do ...

  • Page 10

    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 phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • 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 planning the electrical installation what this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 to which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 15

    Table of contents 15 installation what this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 moving the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 16

    Table of contents 16 note on terminal labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89 note on external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9...

  • Page 17

    Table of contents 17 technical data what this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 iec data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 18

    Table of contents 18 “c-tick” marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129 definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 19: About This Manual

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

  • Page 20

    About this manual 20 the acs800-02/u2 describes the drive. Planning the electrical installation instructs on the motor and cable selection, the protections and the cable routing. Installation instructs how to place, mount and wire the drive. Motor control and i/o board (rmio) shows external control ...

  • Page 21

    About this manual 21 product and service inquiries address any inquiries about the product to your local abb representative, quoting the type code and serial number of the unit in question. A listing of abb sales, support and service contacts can be found by navigating to abb website and selecting d...

  • Page 22

    About this manual 22 phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 23: The Acs800-02/u2

    The acs800-02/u2 23 the acs800-02/u2 what this chapter contains this chapter describes the construction and operating principle of the drive in short. The acs800-02/u2 the acs800-02 is a free-standing drive for controlling ac motors. In the basic unit, the cabling direction is from below. When an op...

  • Page 24

    The acs800-02/u2 24 enclosure extension the extension can be used for accommodating customer equipment; it is also automatically added whenever required by factory-installed options such as • switch fuse (always included with the enclosure extension) • line contactor with category 0 emergency stop d...

  • Page 25

    The acs800-02/u2 25 control panel 0j400 no control panel, leds on the panel mounting platform included i/o l504 additional terminal block x2 (+c111 required) l505 thermistor relay (1 or 2 pcs, +c111 required) l506 pt100 relay (3 pcs, +c111 required) l... Refer to acs800 ordering information (en code...

  • Page 26

    The acs800-02/u2 26 main circuit and control diagram this diagram shows the control interfaces and the main circuit of the drive. Specialities p901 coated boards p904 extended warranty type code selections for the acs800-u2 selection alternatives ~ = ~ = motor control and i/o board (rmio) external c...

  • Page 27

    The acs800-02/u2 27 operation this table describes the operation of the main circuit in short. Printed circuit boards the drive contains the following printed circuit boards as standard: • main circuit board (aint) • motor control and i/o board (rmio-02) with a fibre optic link to the aint board • i...

  • Page 28

    The acs800-02/u2 28 phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 29

    Planning the electrical installation 29 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 30

    Planning the electrical installation 30 3. Check that the motor voltage rating meets the application requirements: see notes 6 and 7 below the requirements table , page 34. 4. Consult the motor manufacturer before using a motor in a drive system where the motor nominal voltage differs from the ac po...

  • Page 31

    Planning the electrical installation 31 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 32

    Planning the electrical installation 32 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-drive end) motor bearings and abb common mode filters are required. The motor manufacturer should be consulted re...

  • Page 33

    Planning the electrical installation 33 * 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 34

    Planning the electrical installation 34 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 35

    Planning the electrical installation 35 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 36

    Planning the electrical installation 36 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 37

    Planning the electrical installation 37 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 38

    Planning the electrical installation 38 protection against short-circuit inside the drive or in the supply cable arrange the protection according to the following guide lines. 1) size the fuses according to instructions given in chapter technical data. The fuses will protect the input cable in short...

  • Page 39

    Planning the electrical installation 39 2) circuit breakers which have been tested by abb with the acs800 can be used. Fuses must be used with other circuit breakers. Contact your local abb representative for the approved breaker types and supply network characteristics. The protective characteristi...

  • Page 40

    Planning the electrical installation 40 power-loss ride-through function the power-loss ride-through function is activated when parameter 20.06 undervoltage ctrl is set to on (default in standard control program). Acs800-07/u7 units without line contactor the power-loss ride-through funtion is not i...

  • Page 41

    Planning the electrical installation 41 prevention of unexpected start the acs800-01/u1, acs800-04/u4, acs800-11/u11, acs800-31/u31 and acs800-07/u7 can be equipped with an optional prevention of unexpected start function according to standards iec/en 60204-1: 1997; iso/dis 14118: 2000 and en 1037: ...

  • Page 42

    Planning the electrical installation 42 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 43

    Planning the electrical installation 43 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 44

    Planning the electrical installation 44 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 45

    Planning the electrical installation 45 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 46

    Planning the electrical installation 46 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 47

    Planning the electrical installation 47 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 48

    Planning the electrical installation 48 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 49

    Planning the electrical installation 49 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 50

    Planning the electrical installation 50 phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 51: Installation

    Installation 51 installation what this chapter contains this chapter describes the mechanical and 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 of thi...

  • Page 52

    Installation 52 warning! The drive is heavy [frame size r7: 110 kg (220 lb), frame size r8: 240 kg (507 lb)].Lift the drive by the upper part only using the lifting lugs attached to the top of the unit. The lower part will be deformed from lifting. Do not remove the pedestal before lifting. Do not t...

  • Page 53

    Installation 53 before installation delivery check the drive is delivered in a box that also contains: • hardware manual • appropriate firmware manuals and guides • optional module manuals • delivery documents. Check that there are no signs of damage. Before attempting installation and operation, ch...

  • Page 54

    Installation 54 requirements for the installation site the drive must be installed in an upright position on floor (or wall). Check the installation site according to the requirements below. Refer to dimensional drawings for frame details. See technical data for the allowed operation conditions of t...

  • Page 55

    Installation 55 it (ungrounded) systems a drive equipped with no emc filter or with emc filter +e210 is suitable for it (ungrounded systems). If the drive is equipped with emc filter +e202, disconnect the filter before connecting the drive to an ungrounded system. For detailed instructions on how to...

  • Page 56

    Installation 56 power cable connection 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) 3) drive module pe * for alternatives, see planning the electrical installation: disconnecting device (disconnecting means) external brake resistor * groundi...

  • Page 57

    Installation 57 installation procedure choose the mounting orientation (a, b, c or d) * space for the installer not included ** space for fan and capacitor replacement not included mounting orientations a and b frame size mounting orientation required free space around the unit for mounting, mainten...

  • Page 58

    Installation 58 remove the pedestal (frame size r7): 1. Remove the lower front covers by undoing the fixing screws. 2. Undo the red screws that fix the pedestal to the frame from front. 3. Undo the red m8 combi screws (8 pcs or 9 pcs with +d150) that connect the busbars of the pedestal to the upper ...

  • Page 59

    Installation 59 remove the pedestal (frame size r8): 1. Remove the lower front covers by undoing the fixing screws. 2. Press the left support leg a little down and turn it left. Let it lock down. Turn the right leg aside in the same way. The legs will prevent the unit from falling down during the in...

  • Page 60

    Installation 60 fix the lead-through plate to the floor: 1. Make a hole in the floor or cable conduit cover below the lead-through plate. See dimensional drawings . 2. Check that the floor is horizontal with a spirit level. 3. Fasten the lead-through plate with screws or bolts. Note: the screws/bolt...

  • Page 61

    Installation 61 units with emc screen (+e202) remove the emc screen by undoing the five fastening screws. Note: the screen must be replaced when the cables have been connected. Tightening torque of the fastening screws is 5 nm (3.7 lbf ft). Lead the power (input, motor and optional brake) cables thr...

  • Page 62

    Installation 62 prepare the power cables: 1. Strip the cables. 2. Twist the shield wires. 3. Bend the conductors to the terminals. 4. Cut the conductors to adequate length. Put the pedestal onto the lead-through plate and check the length of the conductors. Remove the pedestal. 5. Crimp or screw cab...

  • Page 63

    Installation 63 lead the control cables through the lead-through plate: 1. Cut holes in the grommets to fit them tightly onto the control cables. 2. Lead the control cables through the lead-through plate and slide the grommets onto the cables. Terminal a b a b hole 1 hole 2 hole 3 hole 1 hole 2 hole...

  • Page 64

    Installation 64 connect the cable lugs to the pedestal: 1. If the lead-through plate is fixed to the floor, undo the fixing screws. 2. Place the pedestal onto the lead-through plate. 3. Fasten the pedestal and the lead-through plate to the floor with the screws through the same holes. 4. Connect the...

  • Page 65

    Installation 65 mounting orientation c (lifting from above) make the installation otherwise as described in mounting orientations a and b but leave the pedestal connected to the frame. • remove the lead-through plate and the lower front and side plates. • lift the drive frame onto the lead-through p...

  • Page 66

    Installation 66 mounting orientation d (optional enclosure extension included) the customer connections of the drive (power cable terminals, i/o terminal blocks, option module slots) are provided in the enclosure extension instead of the actual drive cubicle. The extension cubicle and the drive cubi...

  • Page 67

    Installation 67 connecting the power cables refer to dimensional drawings for terminal locations and hole sizes. The same screw can be used for connecting two cable lugs (on both sides of the busbar). Connecting the power cables of units without emc filter +e202. Frame sizes r7 and r8. Step instruct...

  • Page 68

    Installation 68 3 cut an adequate hole to the rubber grommet in the lead-through plate and lead the motor cable through the grommet and the conductive sleeve into the cabinet. 4 peel off 3 to 5 cm of the outer insulation of the cable above the lead-through plate for the 360 ° high-frequency earthing...

  • Page 69

    Installation 69 11 it is recommended to make a 360 degrees grounding for the input cable in the same way as for the motor cable. 12 connect the twisted shield of the input cable to the pe busbar of the cabinet. 13 connect the phase conductors of the input cable to the u1, v1 and w1 terminals. 14 fas...

  • Page 70

    Installation 70 3 cut an adequate hole to the rubber grommet in the lead-through plate and lead the motor cable through the grommet and the conductive sleeve into the cabinet. 4 peel off 3 to 5 cm of the outer insulation of the cable below the lead-through plate for the 360 ° high-frequency earthing...

  • Page 71

    Installation 71 11 it is recommended to make a 360 degrees grounding for the input cable in the same way as for the motor cable. 12 connect the twisted shield of the input cable to the pe busbar of the cabinet. 13 connect the phase conductors of the input cable to the u1, v1 and w1 terminals. 14 fas...

  • Page 72

    Installation 72 3 cut an adequate hole to the rubber grommet in the lead-through plate and lead the motor cable through the grommet and the conductive sleeve into the cabinet. 4 peel off 3 to 5 cm of the outer insulation of the cable above the lead-through plate for the 360 ° high-frequency earthing...

  • Page 73

    Installation 73 11 it is recommended to make a 360 degrees grounding for the input cable in the same way as for the motor cable. 12 connect the twisted shield of the input cable to the pe busbar of the cabinet. 13 connect the phase conductors of the input cable to the u1, v1 and w1 terminals. 14 fas...

  • Page 74

    Installation 74 3 cut an adequate hole to the rubber grommet in the lead-through plate and lead the motor cable through the grommet and the conductive sleeve into the cabinet. 4 peel off 3 to 5 cm of the outer insulation of the cable above the lead-through plate for the 360 ° high-frequency earthing...

  • Page 75

    Installation 75 enclosure extension layout there are two main layouts of the enclosure extension, one for each cabling direction. The pictures below show both the bottom and top entry/exit layouts of the enclosure extension. 11 it is recommended to make a 360 degrees grounding for the input cable in...

  • Page 76

    Installation 76 bottom cable entry/exit (r7) *a dd iti o na l t e rm ina l bl o ck r m io bo ar d *a ux iliar y v ol tage tran sfo rme r *li n e co n tac to r switc h fu se *s ta rt /s to p s to p sw itch *c on trol v o lta g e fus e s *the rm is to r/pt1 0 0 rel a ys *l in e c ont act or co ntrol r...

  • Page 77

    Installation 77 top cable entry/exit (r7) *a ddit ion al term in al bl oc k *a ux ili ary vo lta g e tr ans form er *l in e c on tac to r s w itch fu se *s ta rt/s to p s top swi tch *th e rm is tor/p t100 re lay s *l in e c o nt ac tor co ntro l re lay s *t er mi nal bl oc k fo r li ne cont act o r...

  • Page 78

    Installation 78 bottom cable entry/exit (r8) *a ddi tio nal ter m inal bl ock *a ux ili ary vo lta g e tra n sform e r *lin e c on tac tor swit ch fus e *s ta rt/s top s top s w itc h *c on trol vo lta ge fus es *t herm is to r/ pt100 rel a ys *li ne con tac tor cont rol r e la ys *t erm in a l blo ...

  • Page 79

    Installation 79 top cable entry/exit (r8) *a dd iti o na l t e rm ina l bl oc k *a uxi liary vo lta ge t rans fo rme r *lin e c on tac tor switc h fu se *s ta rt/s top s top swi tch *c on tr ol vo lta g e f u se s *th e rmi st o r /pt1 00 rel a ys *l in e c o nt ac tor co ntro l re lay s *t erm ina ...

  • Page 80

    Installation 80 main wiring diagram the diagram below presents the main wiring of the enclosure extension. Note that the diagram includes optional components (marked *) which are not always included in the delivery. En cl osu re e xte ns ion ac s800 -02 driv e cub ic le *x 2 term in al bl oc k *m ot...

  • Page 81

    Installation 81 routing the control/signal cables inside the cubicle units without an enclosure extension frame size r7 secure the cables with cable ties to these holes. Secure the cables with cable ties to the holes in the side bracket of the capacitor pack. Lead the cables through the cushions. Th...

  • Page 82

    Installation 82 units with enclosure extension cable entries with grommets for multiple cable diameters are provided. The following diagram gives an example of signal/control cabling routing inside the cubicle. X2 rmio secure the cables with cable ties to these holes. Phone: 800.894.0412 - fax: 888....

  • Page 83

    Installation 83 connecting the control cables connect the control cables as described below. Connect the conductors to the appropriate detachable terminals of the rmio board (refer to chapter motor control and i/o board (rmio) ).Tighten the screws to secure the connection. Connecting the shield wire...

  • Page 84

    Installation 84 settings of the cooling fan transformer the voltage transformer of the cooling fan (t41) is located at the top of the drive module. Setting of the auxiliary voltage transformer of the line contactor option adjust the setting of the transformer (t1, located in the enclosure extension)...

  • Page 85

    Installation 85 pulse encoder module cabling fibre optic link a ddcs fibre optic link is provided via the rdco optional module for pc tools, master/follower link, ndio, ntac, naio, aima i/o module adapter and fieldbus adapter modules of type nxxx. See rdco user’s manual [3afe64492209 (english)] for ...

  • Page 86

    Installation 86 fill-in user connections diagram the following diagram is a fill-in template for the user’s power and control cable connections of units without enclosure extension. Factory macro configurations of acs800 standard control program are shown. For other programs and macros, refer to the...

  • Page 87

    Installation 87 wiring diagram template phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 88

    Installation 88 phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 89

    Motor control and i/o board (rmio) 89 motor control and i/o board (rmio) what this chapter contains this chapter shows • external control connections to the rmio board for the acs800 standard control program (factory macro) • specifications of the inputs and outputs of the board. To which products t...

  • Page 90

    Motor control and i/o board (rmio) 90 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 91

    Motor control and i/o board (rmio) 91 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 92

    Motor control and i/o board (rmio) 92 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 93

    Motor control and i/o board (rmio) 93 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 94

    Motor control and i/o board (rmio) 94 relay outputs three programmable relay outputs switching capacity 8 a at 24 vdc or 250 vac, 0.4 a at 120 vdc minimum continuous current 5 ma rms at 24 vdc maximum continuous current 2 a rms insulation test voltage 4 kvac, 1 minute ddcs fibre optic link with opti...

  • Page 95

    Motor control and i/o board (rmio) 95 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 96

    Motor control and i/o board (rmio) 96 phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 97: Installation Checklist

    Installation checklist 97 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 98

    Installation checklist 98 phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 99: Maintenance

    Maintenance 99 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 100

    Maintenance 100 layout the layout stickers of the drive are shown below. The stickers show all possible components. Not all of them are present in each delivery or described here. Designation component a49 control panel a41 motor control and i/o board (rmio) y41 cooling fan c_ capacitors code: 64572...

  • Page 101

    Maintenance 101 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 h...

  • Page 102

    Maintenance 102 replacing the fan(s) of the enclosure extension one or two fans are fastened to the inside of the roof. In addition, a fan is located at the side of the enclosure extension in the largest frame size r8 units for first environment (+e202): with bottom entry/exit at the left-hand side,...

  • Page 103

    Maintenance 103 replacing the fan (r7) 1. Remove the upper front cover and disconnect the control panel cables. 2. Disconnect the discharging resistor wire. 3. Remove the dc capacitor pack by undoing the red fixing screws and pulling the pack out. 4. Disconnect the fan supply wires (detachable conne...

  • Page 104

    Maintenance 104 replacing the fan (r8) 1. Remove the front covers by undoing the fixing screws and disconnecting the control panel cable. 2. Disconnect the fan capacitor and power supply wires. 3. Remove the fan capacitor. 4. Units without enclosure extension: disconnect the power supply (a), fibre ...

  • Page 105

    Maintenance 105 capacitors the drive intermediate circuit employs several electrolytic capacitors. Their lifespan is at least 90 000 hours depending on the operating time of the drive, loading and ambient temperature. Capacitor life can be prolonged by lowering the ambient temperature. It is not pos...

  • Page 106

    Maintenance 106 replacing the capacitor pack (r8) 1. Remove the upper front covers and disconnect the control panel cable. Remove the side plate equipped with the control panel mounting slot. 2. Disconnect the discharging resistor wires. 3. Undo the fastening screws. 4. Lift the capacitor pack out. ...

  • Page 107

    Maintenance 107 module replacement of units with the enclosure extension 1. Remove the upper front cover and disconnect the control panel cables. 2. Remove the lower front cover. 3. Undo the fastening screws of the pedestal. 4. Disconnect the pedestal from the drive module by undoing the connection ...

  • Page 108

    Maintenance 108 leds this table describes leds of the drive. Where led when the led is lit rmio board red drive in fault state green the power supply on the board is ok. Control panel mounting platform red drive in fault state green the main + 24 v power supply for the control panel and the rmio boa...

  • Page 109: Technical Data

    Technical data 109 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 rating...

  • Page 110

    Technical data 110 1) 50% overload is available for one minute every 5 minutes if ambient temperature is less than 25 °c. If ambient temperature is 40 °c, max. Available overload is 37%. 2) 50% overload is available for one minute every 5 minutes if ambient temperature is less than 30 °c. If ambient...

  • Page 111

    Technical data 111 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 112

    Technical data 112 fuses gg and ar fuses for protection against short-circuit in the input power cable or drive are listed below. Either fuse type may be used if it operates rapidly enough. Choose between gg and ar fuses according to the table under quick guide for selecting between gg and ar fuses ...

  • Page 113

    Technical data 113 the calculated short-circuit current 9.7 ka is higher than the minimum short-circuit current of the drive gg fuse type ofaf3h500 (8280 a). -> the 500 v gg fuse (abb control ofaf3h500) can be used. Fuse tables ultrarapid (ar) fuses acs800-02 size input current a min. Short- circuit...

  • Page 114

    Technical data 114 three-phase supply voltage 525 v, 550 v, 575 v, 600 v, 660 v or 690 v -0140-7 126 1520 350 68 500 690 bussmann 170m3818 din1* -0170-7 156 1520 350 68 500 690 bussmann 170m3818 din1* -0210-7 191 1610 400 74 000 690 bussmann 170m5808 din2* -0260-7 217 1610 400 74 000 690 bussmann 17...

  • Page 115

    Technical data 115 three-phase supply voltage 380 v, 400 v, 415 v, 440 v, 460 v, 480 v or 500 v -0170-5 191 3820 250 550 000 500 abb control ofaf1h250 1 -0210-5 243 4510 315 1 100 000 500 abb control ofaf2h315 2 -0260-5 291 4510 315 1 100 000 500 abb control ofaf2h315 2 -0320-5 424 8280 500 2 900 00...

  • Page 116

    Technical data 116 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. Not...

  • Page 117

    Technical data 117 note 2: the table is not intended for transformer selection - that must be done separately. The following parameters can effect on the correct operation of the protection: • cable length, i.E. The longer the cable the weaker the fuse protection, as the long cable limits the fault ...

  • Page 118

    Technical data 118 cable entries mains, motor and brake resistor cable terminal sizes (per phase), maximum accepted cable diameters and tightening torques are given below. The maximum allowed width of the cable lug is 38 mm. * m10 in the enclosure extension, tightening torque 30…44 nm dimensions, we...

  • Page 119

    Technical data 119 nema data ratings the nema ratings for the acs800-u2 and acs800-02 with 60 hz supplies are given below. The symbols are described below the table. For sizing, derating and 50 hz supplies, see iec data . 1) available if ambient temperature is less than 30 °c (86 °f). If ambient tem...

  • Page 120

    Technical data 120 3) 50% overload is allowed for one minute every five minutes if ambient temperature is less than 30 °c. 40% overload is allowed if ambient temperature is 40 °c. 4) available if ambient temperature is less than 30 °c (86 °f). If ambient temperature is 40 °c (104 °f), i 2n is 704 a....

  • Page 121

    Technical data 121 ul class t and l fuses acs800-u2 type input current fuse a a v manufacturer type ul class three-phase supply voltage 208 v, 220 v, 230 v or 240 v -0080-2 201 250 600 bussmann jjs-250 t -0100-2 239 300 600 bussmann jjs-300 t -0120-2 285 400 600 bussmann jjs-400 t -0140-2 391 500 60...

  • Page 122

    Technical data 122 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 123

    Technical data 123 cable entries input, motor and brake resistor cable terminal sizes (per phase) and tightening torques are given below. For units without enclosure extension, one hole cable lugs (1/2 inch diameter) can be used. The maximum allowed width of the cable lug is 1.5 inches. For units wi...

  • Page 124

    Technical data 124 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 short-circuit withstand...

  • Page 125

    Technical data 125 cooling method internal fan, flow direction from front to top free space around the unit see chapter installation . Cooling air flow see iec data. Degrees of protection ip 21 (ul type 1) ambient conditions environmental limits for the drive are given below. The drive is to be used...

  • Page 126

    Technical data 126 materials drive enclosure • pc/abs 2.5 mm, colour ncs 1502-y (ral 90021 / pms 420 c) • hot-dip zinc coated steel sheet 1.5 to 2.5 mm, thickness of coating 100 micrometres, colour ncs 1502-y package plywood and wood. Plastic covering of the package: pe-ld, bands pp or steel. Dispos...

  • Page 127

    Technical data 127 ce marking a ce mark is attached to the drive to verify that the unit follows the provisions of the european low voltage and emc directives (directive 73/23/eec, as amended by 93/68/eec and directive 89/336/ eec, as amended by 2004/108ec). Definitions emc stands for electromagneti...

  • Page 128

    Technical data 128 second environment (drive of category c3) the drive complies with the standard with the following provisions: 1. The drive is equipped with emc filter +e210. The filter is suitable for tn (earthed) and it (unearthed) systems. 2. The motor and control cables are selected as specifi...

  • Page 129

    Technical data 129 “c-tick” marking “c-tick” marking is required in australia and new zealand. A “c-tick” mark is attached to each drive in order to verify compliance with the relevant standard (iec 61800-3 (2004) – adjustable speed electrical power drive systems – part 3: emc product standard inclu...

  • Page 130

    Technical data 130 second environment (drive of category c3) the drive complies with the standard with the following provisions: 1. The drive is equipped with emc filter +e210. The filter is suitable for tn (earthed) and it (unearthed) systems. 2. The motor and control cables are selected as specifi...

  • Page 131

    Technical data 131 ul/csa markings the acs800-02 and acs800-u2 arec-ul us listed and csa marked. The approvals are valid with rated voltages (up to 600 v). Ul the drive is suitable for use on a circuit capable of delivering not more than 100 ka rms symmetrical amperes at the drive nominal voltage (6...

  • Page 132

    Technical data 132 phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 133: Dimensional Drawings

    Dimensional drawings 133 dimensional drawings the dimensions are given in milllimetres and [inches]. Phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 134

    Dimensional drawings 134 frame size r7 u s g lan d/ co ndu it pla te 645797 46 h phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 135

    Dimensional drawings 135 frame size r8 3a f e 64 56416 1-d u s gl an d/c o n dui t p la te phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 136

    Dimensional drawings 136 frame size r7 with enclosure extension – bottom entry 64625 942 1 /2 - b flo o r floor 6 6 phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 137

    Dimensional drawings 137 64625 942 2 /2 - c phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 138

    Dimensional drawings 138 frame size r7 with enclosure extension – top entry 646 26264 1/2 - c flo o r 6 phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 139

    Dimensional drawings 139 6462 6264 2/2 - c phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 140

    Dimensional drawings 140 frame size r8 with enclosure extension – bottom entry 3a f e 6462 6388 1 /2 - b floor floor 6 phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 141

    Dimensional drawings 141 3a f e 646 26388 2/2 - b phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 142

    Dimensional drawings 142 frame size r8 with enclosure extension – top entry 3a f e 646 26370 1/2 - c flo or phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 143

    Dimensional drawings 143 3a f e 646 26370 2/2 - c phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 144

    Dimensional drawings 144 phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 145: Resistor Braking

    Resistor braking 145 resistor braking what this chapter contains this chapter describes how to select, protect and wire brake choppers and resistors. The chapter also contains the technical data. To which products this chapter applies this chapter applies to the acs800-01/u1 (frame sizes r2 to r6), ...

  • Page 146

    Resistor braking 146 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 147

    Resistor braking 147 400 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 148

    Resistor braking 148 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 149

    Resistor braking 149 optional brake chopper and resistor(s) for the acs800-02/u2, acs800-04/ 04m/u4 and acs800-07/u7 the nominal ratings for dimensioning the brake resistors for the acs800-02/u2, acs800-04/04m/u4 and acs800-07/u7 are given below at an ambient temperature of 40 °c (104 °f). Acs800 ty...

  • Page 150

    Resistor braking 150 690 v units -0070-7 r6 - - - 45 safur90f575 8.00 1800 4.5 -0100-7 r6 - - - 55 safur80f500 6.00 2400 6 -0120-7 r6 - - - 75 safur80f500 6.00 2400 6 -0140-7 r7 125 5) 110 90 75 safur80f500 6.00 2400 6 -0170-7 r7 125 6) 110 90 75 safur80f500 6.00 2400 6 -0210-7 r7 125 6) 110 90 75 s...

  • Page 151

    Resistor braking 151 all braking resistors must be installed outside the converter module. The resistors are built in an ip 00 metal frame. The 2xsafur and 4xsafur resistors are connected in parallel. Note: the safur resistors are not ul listed. Resistor installation and wiring all resistors must be...

  • Page 152

    Resistor braking 152 use the cable type used for drive input cabling (refer to chapter technical data) to ensure the input fuses will also protect the resistor cable. Alternatively, two- conductor shielded cable with the same cross-sectional area can be used. The maximum length of the resistor cable...

  • Page 153

    Resistor braking 153 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 154

    Resistor braking 154 phone: 800.894.0412 - fax: 888.723.4773 - web: www.Clrwtr.Com - email: info@clrwtr.Com.

  • Page 155

    Non-abb du/dt filter selection 155 non-abb du/dt filter selection what this chapter contains this chapter contains guidelines for selecting and installing a non-abb du/dt filter with the drive. When a du/dt filter must be used a du/dt filter must be used with drives of voltages from 500 v to 690 v a...

  • Page 156

    Non-abb du/dt filter selection 156 6. The motor cable does not exceed the maximum length specified by the filter manufacturer and acs800-02/u2 hardware manual. 7. Maximum output frequency does not exceed the limit specified by the filter manufacturer and 300 hz specified by the drive. Phone: 800.894...