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ABB ACS850-04 series Hardware Manual - Selecting The Control Cables

Manual is about: Standard Control Program

Summary of ACS850-04 series

  • Page 1

    Abb machinery drives hardware manual acs850-04 drive modules (160 to 560 kw, 200 to 700 hp).

  • Page 2

    List of related manuals you can find manuals and other product documents in pdf format on the internet. See section document library on the internet on the inside of the back cover. For manuals not available in the document library, contact your local abb representative. Drive hardware manuals and g...

  • Page 3: Hardware Manual

    Acs850-04 drive modules 160 to 560 kw (200 to 700 hp) hardware manual 3aua0000081249 rev c en effective: 2013-04-11 2013 abb oy. All rights reserved..

  • Page 5: Table Of Contents

    Table of contents 5 table of contents list of related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 table of contents safety instructions what this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 6

    Table of contents 6 layout examples, door closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 layout example, door open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 arranging the grounding...

  • Page 7

    Table of contents 7 relay cable type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 control panel cable length and type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 routing the cables ...

  • Page 8

    Table of contents 8 mounting procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 assembly drawing of installing the drive module to the cabinet (frame g1) . . . . . . . . . . . . . .93 assembly drawing of installing the drive mo...

  • Page 9

    Table of contents 9 cleaning the interior of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 clea...

  • Page 10

    Table of contents 10 csa marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138 “c-tick” marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 11

    Table of contents 11 du/dt filters what this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 du/dt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 12

    Table of contents 12.

  • Page 13: Safety Instructions

    Safety instructions 13 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. ...

  • Page 14: Maintenance

    Safety instructions 14 safety in installation and maintenance electrical safety 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 ...

  • Page 15: •

    Safety instructions 15 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 ...

  • Page 16

    Safety instructions 16 permanent magnet motor drives these are additional warnings concerning permanent magnet motor drives. Warning! Ignoring the instructions can cause physical injury or death, or damage to the equipment. • do not work on the drive when the permanent magnet motor is rotating. Also...

  • Page 17: •

    Safety instructions 17 general safety 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: • - lift the drive module using the lifting lugs attached to the top and base ...

  • Page 18: •

    Safety instructions 18 fiber optic cables - push the drive module into the cabinet and pull it from the cabinet carefully preferably with help from another person as shown below. Keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back. Use safe...

  • Page 19: •

    Safety instructions 19 printed circuit boards safe start-up and operation general safety these warnings are intended for all who plan the operation of the drive or operate the drive. Permanent magnet motor drives warning! Do not run the motor over the rated speed. Motor overspeed leads to overvoltag...

  • Page 20

    Safety instructions 20

  • Page 21: Introduction to The Manual

    Introduction to the manual 21 introduction to the 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...

  • Page 22

    Introduction to the manual 22 start-up refers to the start-up instructions of the cabinet-installed drive. Fault tracing describes the led indications and refers to the fault tracing instructions of the drive. Maintenance contains preventive maintenance instructions. Technical data contains the tech...

  • Page 23

    Introduction to the manual 23 check the installation site. Fasten the base of the cabinet to floor. Checking the installation site (page 73 ) ambient conditions (page 134 ) planning the cabinet installation (page 37 ) route the cables. Routing the cables (page 60 ) check the insulation of the supply...

  • Page 24: Terms And Abbreviations

    Introduction to the manual 24 terms and abbreviations connect the external control cables to the drive control unit. Connecting the control cables (page 95 ) control cable connection procedure of units with internal control unit (option +p905) , page 108 check the installation. Installation checklis...

  • Page 25

    Introduction to the manual 25 frame (size) size of the drive module. The drive modules described in this manual are of frame size g1 and g2. Fsca-01 optional modbus adapter htl high-threshold logic igbt insulated gate bipolar transistor; a voltage-controlled semiconductor type widely used in convert...

  • Page 26

    Introduction to the manual 26.

  • Page 27: Product Overview

    Operation principle and hardware description 27 operation principle and hardware description what this chapter contains this chapter describes the operating principle and construction of the drive module in short. Product overview the acs850-04 is a drive module for controlling asynchronous ac induc...

  • Page 28

    Operation principle and hardware description 28 layout the components of the standard unit are shown below. Item description a drive module 1 lifting lugs 2 fastening bracket 3 input cable connection busbars and optional dc+ and dc- busbars (+h356) 4 circuit board compartment 5 power supply and fibe...

  • Page 29

    Operation principle and hardware description 29 12 base fastening screws 13 handle for pulling the drive module out of the cabinet 14 pedestal guide plate 15 telescopic extraction and insertion ramp 16 top guide plate 17 optional common mode filter (+e208) 18 grounding busbar b control unit (jcu) 1 ...

  • Page 30

    Operation principle and hardware description 30 the drive module and optional selections are shown below: control unit and control panel variations and cabling panels. Item description a drive module 1 input power cabling panel to be fastened to the cabinet (+h381 or +h383) 2 output power cabling pa...

  • Page 31

    Operation principle and hardware description 31 the control unit layout is shown below (cover assembly and protective coverings of the slots removed). Slots 1 and 2 for optional i/o extension and encoder/resolver interface modules slot 3 for optional fieldbus adapter module relay outputs +24vd digit...

  • Page 32

    Operation principle and hardware description 32 power connections and control interfaces the diagram shows the power connections and control interfaces of the drive module. Slot 1 and slot 2 i/o extension modules (fio-01, fio-11, fio-21) and/or encoder or resolver interface modules (fen-01, fen-11, ...

  • Page 33

    Operation principle and hardware description 33 external control unit connection cables the cables for connecting the drive module and control panel to the control unit are shown below. See sections connecting the external control unit to the drive module (page 97 ) and connecting a pc (page 108 ) f...

  • Page 34: Type Designation Label

    Operation principle and hardware description 34 type designation label the type designation label includes an iec and nema rating, ce and culus, and csa markings, a type designation and a serial number, which allow individual recognition of each unit. The type designation label is located on the fro...

  • Page 35: Type Designation Key

    Operation principle and hardware description 35 type designation key the type designation contains information on the specifications and configuration of the drive module. The first digits from left express the basic configuration. The optional selections are given thereafter, separated by plus sign...

  • Page 36

    Operation principle and hardware description 36 fieldbus adapter modules k451 fdna-01 devicenet™ fieldbus adapter module k452 flon-01 lonworks ® fieldbus adapter module k454 fpba-01 profibus dp fieldbus adapter module k457 fcan-01 canopen fieldbus adapter module k458 fsca-01 modbus fieldbus adapter ...

  • Page 37: Limitation Of Liability

    Planning the cabinet installation 37 planning the cabinet installation what this chapter contains this chapter guides in planning drive cabinets and installing the drive module into a user-defined cabinet so that the front of the module faces the cabinet door. The chapter gives cabinet layout exampl...

  • Page 38

    Planning the cabinet installation 38 layout examples, door closed this diagram shows a cabinet layout example with the input power cable lead- through from top and the motor cable lead-through from bottom. Layout example, door open this diagram shows a layout example when optional cabling panels are...

  • Page 39

    Planning the cabinet installation 39 1 supporting frame of the cabinet 9 jcu control unit. 2 vertical (2a, 2b) and horizontal (2c, 2d) air baffles that separate the cool and hot areas (leak-proof lead-throughs). See also page 46 . Note : with an internal control unit (option +p905), the air inlet 17...

  • Page 40: Tightening Torques

    Planning the cabinet installation 40 note 1: the power cable shields can also be grounded to the drive module grounding terminals. Note 2: see also section required free space , page 47 . Arranging the grounding inside the cabinet arrange the grounding of the drive module by leaving the contact surf...

  • Page 41

    Planning the cabinet installation 41 planning the cabinet placement on a cable channel note the following when planning to place the cabinet on a cable channel: • the cabinet structure must be sturdy enough. If the whole cabinet base will not be supported from below, the cabinet weight will lie on t...

  • Page 42

    Planning the cabinet installation 42 • 360° high frequency grounding of the cable shields at the cable lead-throughs improves the emc shielding of the cabinet. • 360° high frequency grounding of the motor cable shields at their entries is recommended. The grounding can be implemented by a knitted wi...

  • Page 43: Planning The Cooling

    Planning the cabinet installation 43 planning the grounding of the cable shields at the cabinet lead-through follow the principle shown below when planning the grounding of the cable shields at the cabinet lead-through. Planning the cooling note following guidelines when planning the cooling of the ...

  • Page 44

    Planning the cabinet installation 44 • leave enough free space around the components to ensure sufficient cooling. Observe the minimum clearances given for each component. For the required free space around the drive module, see page 47 . • also ventilate the heat dissipated by cables and other addi...

  • Page 45

    Planning the cabinet installation 45 preventing the recirculation of hot air prevent hot air circulation outside the cabinet by leading the outcoming hot air away from the area where the inlet air to the cabinet is taken. Possible solutions are listed below: • gratings that guide air flow at the air...

  • Page 46

    Planning the cabinet installation 46 1a 7 pe u1 v1 w1 w2 v2 u2 3 2a 2c 2b 3 c c c – c b b a a 2a 2c b - b a - a 2c 3 2a 2a 2b 2c 3 2d 2a 2d 4 5 6 x y x y 2e 2e 1b 2d 2e 2d 3 2b 2b.

  • Page 47: Required Free Space

    Planning the cabinet installation 47 required free space free space around the drive module is needed for ensuring that sufficient cooling air flows through the module and the module cools properly. Free space at the top of the drive module the required free space at the top of the module is shown b...

  • Page 48

    Planning the cabinet installation 48 planning the placement of the control panel note the following alternatives when planning the placement of the control panel: • the control panel can be snapped on the control unit of the drive. See page 30 . • the control panel can be mounted onto the cabinet do...

  • Page 49

    Planning the electrical installation 49 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 50

    Planning the electrical installation 50 protecting the motor insulation and bearings the drive employs modern igbt inverter technology. Regardless of frequency, the drive output comprises pulses of approximately the drive dc bus voltage with a very short rise time. The pulse voltage can almost doubl...

  • Page 51

    Planning the electrical installation 51 example 1: when the supply voltage is 440 v and the drive is operating in the 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 withstands this vol...

  • Page 52

    Planning the electrical installation 52 * 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, check wit...

  • Page 53

    Planning the electrical installation 53 additional requirements for explosion-safe (ex) motors if you will use an explosion-safe (ex) motor, follow the rules in the requirements table above. In addition, consult the motor manufacturer for any further requirements. Additional requirements for hxr and...

  • Page 54

    Planning the electrical installation 54 additional requirements for non-abb high-output and ip23 motors the rated output power of high output motors is higher than what is stated for the particular frame size in en 50347:2001. The table below shows the requirements for random-wound and form-wound no...

  • Page 55

    Planning the electrical installation 55 additional data for 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 s...

  • Page 56: Selecting The Power Cables

    Planning the electrical installation 56 selecting the power cables general rules dimension the input power and motor cables according to local regulations : • dimension the cable to carry the drive load current. See chapter technical data for the rated currents. • select a cable rated for at least 7...

  • Page 57

    Planning the electrical installation 57 typical power cable sizes the table below gives copper and aluminium cable types with concentric copper shield for the drives with nominal current. See also terminal and lead-through data for the power cables on page 129. 1) the cable sizing is based on max. 9...

  • Page 58

    Planning the electrical installation 58 alternative power cable types the power cable types that can be used with the drive are represented below. Motor cable shield if the motor cable shield is used as the sole protective earth conductor of the motor, ensure that the conductivity of the shield is s...

  • Page 59: Selecting The Control Cables

    Planning the electrical installation 59 additional us requirements use type mc continuous corrugated aluminum armor cable with symmetrical grounds or shielded power cable for the motor cables if metallic conduit is not used. For the north american market, 600 v ac cable is accepted for up to 500 v a...

  • Page 60: Routing The Cables

    Planning the electrical installation 60 a double-shielded cable is the best alternative for low-voltage digital signals but single-shielded twisted pair cable is also usable. Signals in separate cables run analog and digital signals in separate, shielded cables. Never mix 24 v dc and 115/230 v ac si...

  • Page 61

    Planning the electrical installation 61 a diagram of the cable routing is shown below. Separate control cable ducts 90 ° min 500 mm (20 in.) motor cable, brake cable input power cable control cables min 200 mm (8 in.) min 300 mm (12 in.) motor cable power cable drive control cables 24 v lead 24 v an...

  • Page 62

    Planning the electrical installation 62 continuous motor cable shield or enclosure for equipment in the motor cable to ensure safety and minimize the emission level when safety switches, contactors, connection boxes or similar equipment are installed in the motor cable between the drive and the moto...

  • Page 63

    Planning the electrical installation 63 protecting the drive and the input power and motor cables against thermal overload 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 th...

  • Page 64: (Option +Q971)

    Planning the electrical installation 64 implementing the emergency stop function for safety reasons, install the emergency stop devices at each operator control station and at other operating stations where emergency stop may be needed. Note: pressing the stop key ( ) on the control panel of the dri...

  • Page 65

    Planning the electrical installation 65 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 66

    Planning the electrical installation 66 implementing a bypass connection if bypassing is required, employ mechanically or electrically interlocked contactors between the motor and the drive and between the motor and the power line. Ensure with interlocking that the contactors cannot be closed simult...

  • Page 67

    Planning the electrical installation 67 switching the motor power supply from drive to direct-on-line 1. Stop the drive and the motor with the drive control panel (drive in the local control mode) or the external stop signal (drive in the remote control mode). 2. Open the main contactor of the drive...

  • Page 68: Example Circuit Diagram

    Planning the electrical installation 68 connecting 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 connected t...

  • Page 69: Installation

    Installation 69 installation what this chapter contains in this chapter, the drive module is installed in a 400 mm wide rittal ts 8 cabinet in a bookshelf way of mounting: the module is placed in an upright position on the cabinet bottom with its front facing the cabinet door. The following rittal p...

  • Page 70

    Installation 70 note 2: installations with input and motor cables of size 4 × 240 mm 2 per phase if resistor cables are to be connected, the lower side plate of the output cabling panel must be removed and the resistor cables lead from side to the terminals of the output cabling panel. Note 3: insta...

  • Page 71

    Installation 71 note 4: mounting the drive module to an assembly panel mount the assembly support as shown below. M4×12 torx.

  • Page 72

    Installation 72 note 5: mounting the rubber grommet of units with optional cabling panels (+h381) installing the input power cables through the rubber grommet of the optional cabling panels provides the degree of protection of ip20 for the unit. Mount the grommet as follows: 1. Cut adequate holes in...

  • Page 73: Safety

    Installation 73 note 6: alternative installation means in addition to the installation examples presented in this chapter, there are a few alternative installation means, such as: • the power cables can be connected directly to the drive module input and output terminals with cable lugs or by busbar...

  • Page 74

    Installation 74 moving and unpacking the unit warning! Follow the safety instructions, page 14 . Ignoring the instructions can cause physical injury or death, or damage to the equipment move the transport package by pallet truck to the installation site. Unpack the package as follows: • cut the band...

  • Page 75

    Installation 75 2 1 6 9 3 5 4 7 8 ramp package contents 1 screw package 2 pe terminal 3 cardboard box 4 feed through 5 pedestal guide plate 6 telescopic extraction and insertion ramp 7 fastening bracket 8 top guide plate 9 support 7 1 2 3 4 5 6 8 output power cabling panel (option +h381 or +h383) pa...

  • Page 76: Checking The Delivery

    Installation 76 checking the delivery check that all items listed under section moving and unpacking the unit are present. 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 i...

  • Page 77

    Installation 77 motor and motor cable check the insulation of the motor and motor cable as follows: 1. Check that the motor cable is disconnected from the drive output terminals u2, v2 and w2. 2. Measure the insulation resistance between each phase conductor and the protective earth conductor using ...

  • Page 78

    Installation 78 overall flowchart of the installation process this flowchart describes the installation process of the units listed under what this chapter contains on page 69 . Step task for instructions, see 1 install the rittal parts, cabinet bottom plate, drive bottom guide plate and top guide a...

  • Page 79

    Installation 79 installing the mechanical accessories into the cabinet for frame g1, see the assembly drawing on page 81 . For frame g2, see the assembly drawing on page 82 . Install the mechanical accessories into the cabinet as follows: 1. If you use a bottom plate, make the bottom plate according...

  • Page 80

    Installation 80 9. Mount the grounding busbar to the input cabling panel (option +h381 or +h383). Back view is shown below. 10.Mount the side guides to the input cabling panel (2 screws for each side guide) and mount the input cabling panel to the punched section. M8×16 torx m8×16 torx frame size g1...

  • Page 81

    Installation 81 assembly drawing (frame g1) 3 a u a 0 00013 2078.

  • Page 82

    Installation 82 assembly drawing (frame g2) 3a u a 00 00132 062.

  • Page 83

    Installation 83 assembly drawing (air baffles) 3a u a 0000 13206 2.

  • Page 84

    Installation 84 connecting the power cables warning! Follow the safety instructions, page 14 . Ignoring the instructions can cause physical injury or death, or damage to the equipment connection diagram 7 5 input output u1 v1 w1 u2 v2 w2 r - acs850-04 u1 v1 w1 3 ~ motor r+ udc+ udc - u2 v2 w2 r - r+...

  • Page 85

    Installation 85 1 for alternatives, see section selecting the supply disconnecting device on page 49. In the mounting example of this chapter, the disconnecting device is not in the same cubicle with the drive module. 2 if a shielded cable is used (not required but recommended) and the conductivity ...

  • Page 86

    Installation 86 power cable connection procedure warning! Follow the instructions in chapter safety instructions . Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Lead the input cables into the inside of the cabinet. Ground the cable shield 360° at the le...

  • Page 87

    Installation 87 note: the input and output power cables must fit inside the area marked with diagonal lines in the image below to avoid chafing of the cables when the drive module is inserted into the cabinet. C a view without cabinet side plate in place. A) 360-degree grounding at the lead-through ...

  • Page 88

    Installation 88 ground the motor cable shield at the motor end as follows: • 360 degrees at the lead-through of the motor terminal box (1) • or by twisting the shield as follows: flattened width > 1/5 · length. Dc connection the udc+ and udc– terminals are intended for common dc configurations of a ...

  • Page 89

    Installation 89 mounting the drive module into the cabinet warning! Follow the safety instructions, page 14 . Ignoring the instructions can cause physical injury or death, or damage to the equipment. Handle the drive module carefully. Make sure that the module does not fall down when moving it on th...

  • Page 90

    Installation 90 mounting procedure 1. Mount the fastening bracket to the drive module. 2. Mount the grounding busbar that has been previously mounted to the input cabling panel to the drive module. Note : the design of the grounding busbar can differ from what is shown in the figure. 1 m8×20 hex m8×...

  • Page 91

    Installation 91 3. Install the extraction and insertion ramp to the cabinet base with two screws. 4. Remove the upper and lower left-side front covers of the drive module. M4×8 combi screws, 2 n· m. 5. Push the drive module carefully into to the cabinet preferably with help from another person. 6. C...

  • Page 92

    Installation 92 3 6a 6b 5 4 8 4 8 6a 6b 7a 7b 7b.

  • Page 93

    Installation 93 assembly drawing of installing the drive module to the cabinet (frame g1) 3a u a 000 01320 78.

  • Page 94

    Installation 94 assembly drawing of installing the drive module to the cabinet (frame g2) 3a u a 0 000132 062.

  • Page 95

    Installation 95 removing the protective covering from the module air outlet warning! Remove the protective covering from the top of the drive module after the installation. If the covering is not removed, the cooling air cannot flow freely through the module and the drive will run to overtemperature...

  • Page 96

    Installation 96 removing the cover assembly of the external control unit the cover assembly needs to be removed before the installation of optional modules and the connection of control cabling. Follow this procedure to remove the cover assembly. The numbers refer to the illustrations below. 1. Pres...

  • Page 97

    Installation 97 fastening the control cable clamp plate fasten the control cable clamp plate either to the top or base of the control unit with four screws as shown below. Connecting the external control unit to the drive module warning! Handle the fiber optic cables with care. When unplugging optic...

  • Page 98

    Installation 98 3aua0000038989 txd = transmitter rxd = receiver jrib v2 v1 v7 v6 1 2 apow jint 2 jrib 1 4 3 jgdr.

  • Page 99

    Installation 99 mounting the external control unit the drive control unit can be fastened on a mounting plate through the fastening holes in its back or by using a din rail. Mounting the external control unit to wall 1. Fasten the fastening screws in the wall. 2. Lift the unit onto the screws and ti...

  • Page 100

    Installation 100 mounting the external control unit vertically on a din rail 1. Fasten the latch (a) to the back of the control unit with three screws. 2. Click the control unit to the rail as shown below (b). Mounting the control unit horizontally on a din rail 1. Fasten the latches (a) to the back...

  • Page 101

    Installation 101 installing optional modules mechanical installation optional modules such as a fieldbus adapters, an i/o extensions and the pulse encoder interfaces are inserted in the optional module slot on the control unit. See page 32 for the available slots. 1. Remove the control unit cover. 2...

  • Page 102

    Installation 102 connecting the control cables to the terminals of the control unit 1. Route the cables to the control unit as shown below. 2. Ground the shields of the control cables at the clamp plate. The shields should be continuous as close to the terminals of the control unit as possible. Only...

  • Page 103

    Installation 103 the shield can also be grounded directly at both ends if they are in the same ground line with no significant voltage drop between the end points.Tighten the screws to secure the connection. 3. Connect the conductors to the appropriate detachable terminals of the control unit. See s...

  • Page 104

    Installation 104 default i/o connection diagram notes: […] denotes default setting with acs850 standard control program (factory macro). See the firmware manual for other macros. *total maximum current: 200 ma the wiring shown is for demonstrative purposes only. Further information of the usage of t...

  • Page 105

    Installation 105 jumpers di/dio grounding selector (located between xd24 and xdi) – determines whether the dignd (ground for digital inputs di1…di5) floats, or if it is connected to diognd (ground for di6, dio1 and dio2). See the jcu isolation and grounding diagram on page 133 . If dignd floats, the...

  • Page 106

    Installation 106 external power supply for the jcu control unit (xpow) external +24 v (minimum 1.6 a) power supply for the control unit can be connected to terminal block xpow. Using an external supply is recommended if • the application requires fast start after connecting the drive to the main sup...

  • Page 107

    Installation 107 warning! As the inputs pictured above are not insulated according to iec 60664, the connection of the motor temperature sensor requires double or reinforced insulation between motor live parts and the sensor. If the assembly does not fulfil the requirement, • the i/o board terminals...

  • Page 108: (Option +P905)

    Installation 108 safe torque off (xsto) for the drive to start, both connections (out1 to in1, and out2 to in2) must be closed. By default, the terminal block has jumpers to close the circuit. Remove the jumpers before connecting an external safe torque off circuitry to the drive. See page 64 . Cont...

  • Page 109: Installation Checklist

    Installation checklist 109 installation checklist what this chapter contains this chapter contains a list for checking the mechanical and electrical installation of the drive. Installation checklist go through the checklist below together with another person. Warning! Follow the safety instructions,...

  • Page 110

    Installation checklist 110 connection of cables to devices, terminal blocks and drive module circuit boards: • cables are connected to terminals tight enough by pulling the cable. • cable termination on terminals chaining is done correctly. • bare conductors are not too far outside the terminal caus...

  • Page 111

    Installation checklist 111 the supply voltage matches the nominal input voltage of the drive. Check the type designation label. The input power cable has been connected to the appropriate terminals, the phase order is right, and the terminals have been tightened. (pull the conductors to check.) appr...

  • Page 112

    Installation checklist 112.

  • Page 113: Start-Up

    Start-up 113 start-up what this chapter contains this chapter refers to the start-up instructions of the drive. Start-up procedure 1. Ensure that the installation of the drive has been checked according to the checklist in chapter installation checklist, and that the motor and driven equipment are r...

  • Page 114

    Start-up 114.

  • Page 115: Fault Tracing

    Fault tracing 115 fault tracing what this chapter contains this chapter describes the fault tracing possibilities of the drive. Leds this table describes leds of the drive module. Warning and fault messages see the firmware manual for the descriptions, causes and remedies of the control program warn...

  • Page 116

    Fault tracing 116.

  • Page 117: Maintenance

    Maintenance 117 maintenance what this chapter contains this chapter contains maintenance instructions of the drive module. Applicability the drive module replacement described in this chapter applies to the rittal ts 8 example installation of chapter installation . The other maintenance instructions...

  • Page 118: Cabinet

    Maintenance 118 note : perform the maintenance tasks of the cabinet (for example, clean the air inlet and outlet filters) when necessary and according to the cabinet manufacturer’s instructions. Consult your local abb service representative for more details on the maintenance. On the internet, go to...

  • Page 119: Heatsink

    Maintenance 119 heatsink the module heatsink fins pick up dust from the cooling air. The drive runs into overtemperature warnings and faults if the heatsink is not clean. Cleaning the interior of the heatsink warning! Follow the safety instructions, page 14 . Ignoring the instructions can cause phys...

  • Page 120: Fans

    Maintenance 120 fans the actual lifespan depends on the running time of the fan, ambient temperature and dust concentration. See the firmware manual for the actual signal which indicates the running time of the cooling fan. For resetting the running time signal after a fan replacement, please contac...

  • Page 121

    Maintenance 121 replacing the main cooling fans warning! Follow the safety instructions, page 14 . Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Remove the drive module out of the cabinet as described in section replacing the drive module on page 122 . ...

  • Page 122: Replacing The Drive Module

    Maintenance 122 replacing the drive module warning! Follow the safety instructions, page 14 . Ignoring the instructions can cause physical injury or death, or damage to the equipment. Handle the drive module carefully. Make sure that the module does not fall down when moving it on the floor and duri...

  • Page 123

    Maintenance 123 9. Pull the drive module carefully out of the cabinet preferably with help from another person. 10.Install the new module in reverse order to the above. 7 3 4 9 5 5 2 2.

  • Page 124: Capacitors

    Maintenance 124 capacitors the drive intermediate circuit employs several electrolytic capacitors. Their lifespan depends on the operating time of the drive, loading and ambient temperature. The lifespan of the capacitor can be prolonged by lowering the ambient temperature. It is not possible to pre...

  • Page 125: Technical Data

    Technical data 125 technical data what this chapter contains this chapter contains the technical specifications of the drive, for example, the ratings, sizes and technical requirements, provisions for fulfilling the requirements for ce and other markings. Ratings the ratings of the drive modules wit...

  • Page 126

    Technical data 126 derating the continuous output currents stated above must be derated if any of the following conditions apply: • ambient temperature exceeds +40 °c (+104 °f) • drive is installed higher than 1000 m above sea level. Note: the final derating factor is a multiplication of all applica...

  • Page 127: Fuses (Iec)

    Technical data 127 fuses (iec) fuses (ul) note 1: see also implementing thermal overload and short-circuit protection on page 62 . Note 2: in multicable installations, install only one fuse per phase (not one fuse per conductor). Note 3: larger fuses than the recommended ones must not be used. Note ...

  • Page 128

    Technical data 128 dimensions, weights and free space requirements for requirements of free space around the drive module, see page 47 . Drive type acs850-04 frame size h1 h2 w1 w2 d1 d2 weight 1 mm mm mm mm mm mm kg -387a-5 g1 1462 1590 305 329 505 515 161 -500a-5 g1 1462 1590 305 329 505 515 161 -...

  • Page 129

    Technical data 129 losses, cooling data and noise terminal and lead-through data for the power cables the maximum accepted cable size is 4 × (3 × 240) mm 2 or 4 × (3 × 500 awg). Screw size for connecting busbars to the drive module input and output busbars: m12, tightening torque 50...75 n·m. Units ...

  • Page 130: Motor Connection Data

    Technical data 130 units without optional cabling panels (no +h381 or +h383) in units without optional cabling panels (option +h381/+h383 not selected), it is possible to use the maximum cable size (4 × (3 × 240) mm2 or 4 × [3 × 500 awg]) only with special cable lugs and additional insulation. For m...

  • Page 131: Dc Connection Data

    Technical data 131 dc connection data drive module type i dc (a) capacitance (mf) acs850-04-387a-5 487 14 acs850-04-500a-5 640 14 acs850-04-580a-5 714 14 acs850-04-650a-5 870 14 acs850-04-710a-5 909 21 acs850-04-807a-5 1033 21 acs850-04-875a-5 1120 21 control unit (jcu-11) connection data power supp...

  • Page 132

    Technical data 132 analog inputs ai1 and ai2 (xai:4 … xai:7). Current/voltage input mode selection by jumpers. See page 105 . Connector pitch 3.5 mm, wire size 1.5 mm 2 current input: –20…20 ma, r in: 100 ohm voltage input: –10…10 v, r in : 200 kohm differential inputs, common mode ±20 v sampling in...

  • Page 133: Efficiency

    Technical data 133 isolation and grounding diagram efficiency approximately 98% at nominal power level degree of protection ip00 (ul type open). With option +h381: ip20 (ul type open). Note: the degree of protection of ip20 requires that the input power cables are installed through the rubber gromme...

  • Page 134: Ambient Conditions

    Technical data 134 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 135: Materials

    Technical data 135 materials drive enclosure • pc/abs 2.5 mm, color ncs 1502-y (ral 9002 / pms 420 c) • hot-dip zinc coated steel sheet 1.5 to 2.5 mm, thickness of coating 100 micrometers, color ncs 1502-y package plywood and cardboard, bands pp. Disposal the main parts of the drive can be recycled ...

  • Page 136: Ce Marking

    Technical data 136 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. The ce marking also verifies that the drive, in regard to its safety functions (such as safe torque off), conforms with the machinery direct...

  • Page 137

    Technical data 137 category c3 the drive complies with the standard with the following provisions: 1. The motor and control cables are selected as specified in the hardware manual. 2. The drive is installed according to the instructions given in the hardware manual. 3. Maximum cable length is 100 me...

  • Page 138: Ul Marking

    Technical data 138 ul marking the drive is culus listed. Ul checklist • the drive is to be used in a heated, indoor controlled environment. The drive must be installed in clean air according to enclosure classification. Cooling air must be clean, free from corrosive materials and electrically conduc...

  • Page 139: Disclaimer

    Technical data 139 disclaimer the manufacturer shall have no obligation with respect to any product which (i) has been improperly repaired or altered; (ii) has been subjected to misuse, negligence or accident; (iii) has been used in a manner contrary to the manufacturer's instructions; or (iv) has f...

  • Page 140

    Technical data 140

  • Page 141: Dimension Drawings

    Dimension drawings 141 dimension drawings what this chapter contains this chapter contains dimension drawings of the drive modules with optional parts for rittal ts 8 cabinet assembly..

  • Page 142

    Dimension drawings 142 frame g1 – drive module dimensions.

  • Page 143: (+H381)

    Dimension drawings 143 frame g1 – drive module dimensions with optional cabling panels (+h381).

  • Page 144

    Dimension drawings 144.

  • Page 145

    Dimension drawings 145 frame g1 – cabling panels (+h383) installed into a rittal ts 8 cabinet.

  • Page 146

    Dimension drawings 146 frame g2 – drive module dimensions.

  • Page 147: (+H381)

    Dimension drawings 147 frame g2 – drive module dimensions with optional cabling panels (+h381).

  • Page 148

    Dimension drawings 148.

  • Page 149

    Dimension drawings 149 frame g2 – cabling panels (+h383) installed into a rittal ts 8 cabinet.

  • Page 150: Frames G1 And G2

    Dimension drawings 150 frames g1 and g2 – bottom plate 3 a u a 0 00008 2240

  • Page 151: Frames G1 And G2

    Dimension drawings 151 frames g1 and g2 – air baffles 3 a u a 0 00013 8986.

  • Page 152

    Dimension drawings 152.

  • Page 153: Example Circuit Diagram

    Example circuit diagram 153 example circuit diagram what this chapter contains this chapter shows an example circuit diagram for a cabinet-installed drive module..

  • Page 154: Example Circuit Diagram

    Example circuit diagram 154 example circuit diagram this diagram is an example for the main wiring of a drive cabinet. Note that the diagram includes components which are not included in a basic delivery (* plus code options, ** other options, *** to be acquired by the customer). ** m o to r t e m p...

  • Page 155: Resistor Braking

    Resistor braking 155 resistor braking what this chapter contains this chapter describes how to select, protect and wire brake resistors. Availability of brake choppers and resistors brake choppers are optionally available as built-in units, indicated in the type description by +d150. External resist...

  • Page 156

    Resistor braking 156 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 / resistor c...

  • Page 157

    Resistor braking 157 protecting the system in fault situations thermal overload protection the brake chopper protects itself and the resistor cables against thermal overload when the cables are dimensioned according to the nominal current of the drive. The drive control program includes a resistor a...

  • Page 158: Mechanical Installation

    Resistor braking 158 maximum cable length the maximum length of the resistor cable(s) is 10 m (33 ft). Emc compliance of the complete installation note: abb has not verified that the emc requirements are fulfilled with external user-defined brake resistors and cabling. The emc compliance of the comp...

  • Page 159: Technical Data

    Resistor braking 159 technical data ratings the ratings for selecting the brake system components are given below at an ambient temperature of 40 °c (104 °f). Check that the braking energy transmitted to the specified resistor(s) in 400 seconds does not exceed e r . See page 155 . Brake resistor con...

  • Page 160

    Resistor braking 160 dimensions and weights 234 300 132 0 Ø 7 345 1270 ght: fur180f460: 32 kg fur125f500: 25 kg fur200f500: 30 kg fur210f575: 27 kg brake resistor type weight (kg) safur125f500 25 safur200f500 30

  • Page 161: Filters

    Du/dt filters 161 d u /d t filters what this chapter contains this chapter describes how to select d u /d t filters for the drive. D u /d t filters when is d u /d t filter needed? See section checking the compatibility of the motor and drive , page 50 . Selection table d u /d t filter types for the ...

  • Page 162

    Du/dt filters 162.

  • Page 163

    Further information product and service inquiries address any inquiries about the product to your local abb representative, quoting the type designation and serial number of the unit in question. A listing of abb sales, support and service contacts can be found by navigating to www.Abb.Com/drives an...

  • Page 164

    3a ua000008 1249 rev c (e n) 201 3- 04 -1 1 contact us www.Abb.Com/drives www.Abb.Com/drivespartners.