ABB ACS850 series Hardware Manual - Heatsink

Manual is about: machinery drive

Summary of ACS850 series

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    Acs850 hardware manual acs850-04 drive modules (55…160 kw, 75…200 hp).

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    Acs850 drive manuals *the delivery includes a multilingual quick installation guide. **the delivery includes a multilingual quick start-up guide. ***included in the delivery with appropriate option device. Drive hardware manuals * acs850-04 drive modules (1.1 to 45 kw) hardware manual – 3aua00000454...

  • Page 3: Hardware Manual

    Acs850-04 drive modules (55…160 kw, 75…200 hp) hardware manual 3aua0000045487 rev b en effective: 2009-07-20 © 2009 abb oy. All rights reserved..

  • 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, the motor, or driven equipme...

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    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 and ...

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    Safety instructions 7 warning! Ignoring the following instructions can cause physical injury or death, or damage to the equipment. • never attempt to repair a malfunctioning drive; contact your local abb representative or authorized service center. • make sure that dust from drilling does not enter ...

  • Page 8: Start-Up and Operation

    Safety instructions 8 start-up and operation these warnings are intended for all who plan the operation of the drive, start up 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 i...

  • Page 9: Table of Contents

    Table of contents 9 table of contents safety instructions what this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

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    Table of contents 10 emc requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 mechanical installation contents of the package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

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    Table of contents 11 checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 s...

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    Table of contents 12 technical data what this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

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    Table of contents 13 braking circuit commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 du/dt and common mode filtering what this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

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    Table of contents 14.

  • Page 15: About This Manual

    About this manual 15 about this manual what this chapter contains this chapter describes the intended audience and contents of this manual. It contains a flowchart of steps in checking the delivery, installing and commissioning the drive. The flowchart refers to chapters/sections in this manual and ...

  • Page 16: Contents

    About this manual 16 contents the chapters of this manual are briefly described below. Safety instructions give safety instructions for the installation, commissioning, operation and maintenance of the drive. About this manual lists the steps in checking the delivery and installing and commissioning...

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    About this manual 17 installation and commissioning flowchart task see plan the installation. Check the ambient conditions, ratings, required cooling air flow, input power connection, compatibility of the motor, motor connection, and other technical data. Select the cables. Planning the cabinet asse...

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    About this manual 18 connect the power cables. Connect the control and the auxiliary control cables. Electrical installation: power cable connection : (page 59 ) and connecting the control cables : (page 65 ) for optional equipment: resistor braking (page 97 ) manuals for any optional equipment chec...

  • Page 19: Terms and Abbreviations

    About this manual 19 terms and abbreviations term/abbreviation explanation emc electromagnetic compatibility. Fio-01 optional digital i/o extension for the acs850. Fio-11 optional analog i/o extension for the acs850. Fio-21 optional analog/digital i/o extension for the acs850. Fen-01 optional ttl en...

  • Page 20: Product Training

    About this manual 20 product and service inquiries address any inquiries about the product to your local abb representative, quoting the type code and serial number of the unit in question. A listing of abb sales, support and service contacts can be found by navigating to www.Abb.Com/drives and sele...

  • Page 21: What This Chapter Contains

    Operation principle and hardware description 21 operation principle and hardware description what this chapter contains this chapter describes the construction and operating principle of the drive in short. The acs850-04 the acs850-04 is an ip20 drive module for controlling ac motors. It is to be in...

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    Operation principle and hardware description 22 power connections and control interfaces the diagram shows the power connections and control interfaces of the drive. Slot 1 slot 2 slot 3 control unit (jcu) fxx fxxx fxx control panel or pc memory unit 1) braking resistor (optional) power unit braking...

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    Operation principle and hardware description 23 main circuit and operation this table describes the operation of the main circuit in short. Component description rectifier converts the three-phase ac voltage to dc voltage. Inverter converts the dc voltage to ac voltage and vice versa. The motor is c...

  • Page 24: Type Code

    Operation principle and hardware description 24 type code the type code contains information on the specifications and configuration of the drive. The first digits from left express the basic configuration (e.G. Acs850-04- 290a-5). The optional selections are given thereafter, preceded by + signs (e...

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    Operation principle and hardware description 25 printed hardware and firmware manuals in specified language (english manuals will be delivered despite of the selection if no manuals in selected language exist) r… +r700: english +r701: german +r702: italian +r703: dutch +r704: danish +r705: swedish +...

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    Operation principle and hardware description 26.

  • Page 27: What This Chapter Contains

    Planning the cabinet assembly 27 planning the cabinet assembly what this chapter contains this chapter guides in planning the installation of a drive module into a user-defined cabinet. The issues discussed are essential for safe and trouble-free use of the drive system. Note: please note that the i...

  • Page 28: Free Space Requirements

    Planning the cabinet assembly 28 free space requirements the modules can be installed side by side. The dimensions of the drive modules are presented in chapter dimension drawings . The free space requirements (valid for both frame sizes) are shown below. The temperature of the cooling air entering ...

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    Planning the cabinet assembly 29 cooling and degrees of protection the cabinet must have enough free space for the components to ensure sufficient cooling. Observe the minimum clearances given for each component. The air inlets and outlets must be equipped with gratings that • guide the air flow • p...

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    Planning the cabinet assembly 30 preventing the recirculation of hot air outside the cabinet 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...

  • Page 31: Cabinet Heaters

    Planning the cabinet assembly 31 cabinet heaters use a cabinet heater if there is a risk of condensation in the cabinet. Although the primary function of the heater is to keep the air dry, it may also be required for heating at low temperatures. When placing the heater, follow the instructions provi...

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    Planning the cabinet assembly 32 360° high frequency grounding of the control cable shields is recommended at their entries. The shields can be grounded by means of conductive shielding cushions pressed against the cable shield from both directions: shielding cushion (conductive) cable cable grommet...

  • Page 33: Mechanical Installation

    Mechanical installation 33 mechanical installation contents of the package the drive is delivered in a box made of plywood and cardboard. The box contains: • drive module, with factory-installed options • one cable clamp plate for control cabling with screws • screw-type terminal blocks to be attach...

  • Page 34: Before Installation

    Mechanical installation 34 before installation check the installation site according to the requirements below. Refer to dimension drawings for frame details. Requirements for the installation site see technical data for the allowed operation conditions of the drive. The drive is to be mounted in an...

  • Page 35: What This Chapter Contains

    Planning the electrical installation 35 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. If the recommendations given by abb are...

  • Page 36: Supply Disconnecting Device

    Planning the electrical installation 36 warning! As the leakage current of the device typically exceeds 3.5 ma, a fixed installation is required according to iec 61800-5-1. Supply disconnecting device install a hand-operated input disconnecting device (disconnecting means) between the ac power sourc...

  • Page 37: Ground Fault Protection

    Planning the electrical installation 37 restrict drive damage and prevent damage to adjoining equipment in case of a short circuit inside the drive. Operating time of the fuses and circuit breakers the operating time depends on the type, the supply network impedance, and the cross-sectional area, ma...

  • Page 38: Safe Torque Off

    Planning the electrical installation 38 safe torque off the drive supports the safe torque off function according to standards pren 61800-5-2; en 954-1 (1997); iec/en 60204-1: 1997; en 61508: 2002 and en 1037: 1996. The safe torque off function disables the control voltage of the power semiconductor...

  • Page 39: Selecting The Power Cables

    Planning the electrical installation 39 selecting the power cables general rules dimension the supply (input power) and motor cables according to local regulations. • the cable must be able to carry the drive load current. See the chapter technical data for the rated currents. • the cable must be ra...

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    Planning the electrical installation 40 alternative power cable types power cable types that can be used with the drive are represented below. Motor cable shield to function as a protective conductor, the shield must have the same cross-sectional area as a phase conductor when they are made of the s...

  • Page 41: Of Inductive Loads

    Planning the electrical installation 41 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 output on the drive is protected with varistors (250 v) against over...

  • Page 42: Routing The Cables

    Planning the electrical installation 42 double-shielded cable is the best alternative for low-voltage digital signals but single-shielded twisted multipair cable (figure b) is also usable. Run analogue and digital signals in separate cables. Relay-controlled signals, providing their voltage does not...

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    Planning the electrical installation 43 a diagram of the cable routing is below. Control cable ducts min 500 mm (20”) control cables min 300 mm (12”) supply cable motor cable motor cable min 500 mm (20”) braking resistor cable 90° 90° drive 90° min 200 mm (20”) supply cable 230 v 24 v 24 v 230 v lea...

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    Planning the electrical installation 44.

  • Page 45: Electrical Installation

    Electrical installation 45 electrical installation what this chapter contains this chapter describes the electrical installation procedure of the drive. Warning! The work described in this chapter may only be carried out by a qualified electrician. Follow the safety instructions on the first pages o...

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    Electrical installation 46 1 2 3 4 5.

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    Electrical installation 47 checking the insulation of the assembly drive do not make any voltage tolerance or insulation resistance tests (e.G. Hi-pot or megger) on any part of the drive as testing can damage the drive. Every drive has been tested for insulation between the main circuit and the chas...

  • Page 48

    Electrical installation 48 connection to an it (ungrounded) power system warning! Before connecting the drive to an it power system [an ungrounded power system or a high resistance-grounded (over 30 ohms) power system] or a corner-grounded power system, the internal emc filtering of the drive must b...

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    Electrical installation 49 4. Remove the screw at the top of the cover assembly. 5. Disconnect the panel cable (if present)..

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    Electrical installation 50 6. Carefully pull the lower part of the base outwards by the two tabs. 7. Lift the cover assembly up..

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    Electrical installation 51 8. Remove the option modules (if any) in options slots 1 and 3. 9. Release the two screws holding the jcu control unit..

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    Electrical installation 52 10. Lift the left-hand edge of the jcu control unit until the connector beneath disengages, then move jcu to the left to remove it. 11. Disconnect the two cables coming to the mounting base of the jcu. 1 2.

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    Electrical installation 53 12. Remove the two screws holding the drive module cover. 13. First slide the cover a bit upwards, then lift off the cover..

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    Electrical installation 54 14. Remove the two screws (marked x2 and x3) on top of the rrfc/rvar circuit board. 15. Refit the module cover and fasten using the screws removed at step 12 . 16. Reconnect the cables that were disconnected at step 11 . 17. Refit the jcu control unit..

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    Electrical installation 55 frame size e: disconnection of internal emc filtering (option +e202 included) 1. Place the drive module on its back on a level surface. 2. Remove the cover assembly and jcu control unit and disconnect the two cables. Follow the same instructions as with frame size e0, step...

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    Electrical installation 56 5. First slide the cover a bit upwards, then lift off the cover. 6. Undo the screw connecting the grounding wire to a standoff right next to the emc filter. Cut off the lug. Discard the screw and the tubular insulator. Standoff covered by insulator emc filter.

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    Electrical installation 57 7. Insulate the end of the grounding wire reliably with insulating tape, tube sleeving and a cable tie..

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    Electrical installation 58 8. Near the top of the module, remove the grounding clip (held by two screws) that connects the varistor board to the module cover. Fasten the removed screws to mount the varistor board. 9. Refit the module cover (top edge first) and fasten using the screws removed at step...

  • Page 59: Power Cable Connection

    Electrical installation 59 power cable connection power cable connection diagram notes: – do not use a non-shielded or asymmetrically-constructed motor cable. It is recommended to use a shielded cable also as an supply (input) cable. – if shielded supply (input) cable is used, and the conductivity o...

  • Page 60

    Electrical installation 60 procedure 1. Remove the plastic shroud covering the main terminals. Lift up with a screw driver from the corner. 2. Connect the twisted shields of the power cables and separate grounding conductors to the grounding terminals of the drive module. 3. Connect the phase conduc...

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    Electrical installation 61 frame size e: cable lug installation (16 to 70 mm 2 [awg6 to awg2/0] cables) u1 v1 w1 u2 v2 w2 r- udc+ r+ udc- input power cable motor cable insulate the ends of the cable lugs with tape or shrink tube 30…44 n·m (22…32 lbf·ft) pe 8 n·m (5.9 lbf·ft).

  • Page 62

    Electrical installation 62 frame size e: screw terminal installation (95 to 240 mm 2 [awg3/0 to 400mcm] cables) grounding the motor cable shield at the motor end for minimum radio frequency interference, ground the cable shield 360 degrees at the lead-through of the motor terminal box or ground the ...

  • Page 63

    Electrical installation 63 dc connection the udc+ and udc– terminals are intended for common dc configurations of a number of acs850 drives, allowing regenerative energy from one drive to be utilised by the other drives in motoring mode. One or more drives are connected to the ac supply depending on...

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    Electrical installation 64 installation of optional modules optional modules such as fieldbus adapters, i/o extensions and encoder interfaces ordered using option codes (see page 24 ) are pre-installed at the factory. Instructions for installing additional modules into the slots on the jcu control u...

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    Electrical installation 65 connecting the control cables control connections to the jcu control unit xpow external power input 24 v dc, 1.6 a +24vi 1 gnd 2 xro1, xro2, xro3 relay output ro1 [ready] 250 v ac / 30 v dc 2 a no 1 com 2 nc 3 relay output ro2 [modulating] 250 v ac / 30 v dc 2 a no 4 com 5...

  • Page 66

    Electrical installation 66 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 86 .) if dignd ...

  • Page 67

    Electrical installation 67 di6 (xdi:6) as a thermistor input 1…3 ptc sensors can be connected to this input for motor temperature measurement. Notes: • do not connect both ends of the cable shields directly to ground. If a capacitor cannot be used at one end, leave that end of the shield unconnected...

  • Page 68

    Electrical installation 68 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, • all i/o termi...

  • Page 69

    Electrical installation 69 grounding and routing the control cables the shields of all control cables connected to the jcu control unit must be grounded at the control cable clamp plate. Use four m4 screws to fasten the plate as shown below (two of the screws are also used to hold the cover mounting...

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    Electrical installation 70 mounting the clamp plate 0.7 n·m (6.2 lbf·in).

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    Electrical installation 71 routing the control cables use shrink tubing or tape to contain strands run cables through the cover mounting bracket remove outer jacket of cable at clamp to expose cable shield. Tighten clamp to 1.5 n·m (13 lbf·in).

  • Page 72

    Electrical installation 72.

  • Page 73: Installation Checklist

    Installation checklist 73 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 74

    Installation checklist 74 there are no tools, foreign objects or dust from drilling inside the drive. The supply (input power) voltage cannot be applied to the output of the drive through a bypass connection. Motor connection box and other covers are in place. Check.

  • Page 75: Maintenance

    Maintenance 75 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 76: Heatsink

    Maintenance 76 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, the heatsink should be checked annually, in a dusty environment more often. Clean the heatsink as follows (when ...

  • Page 77

    Maintenance 77 fan replacement (frame e) 1. Undo the fixing screw of the cooling fan holder. 2. Slide out the cable connector and disconnect it. 3. Remove the cooling fan holder and replace the fan onto the holder’s pins. Install the cooling fan holder in reverse order. Frame size e, bottom view 1 3.

  • Page 78: Capacitors

    Maintenance 78 additional cooling fan replacement (frame e0) the fan is located on top of the module. 1. Undo the fixing screw of the cooling fan holder (1 pc pz2 screw). 2. Pull the fan holder out. 3. Disconnect the fan cable. 4. Undo the fastening screws of the fan (4 pcs pz2 screws, circled in th...

  • Page 79: Other Maintenance Actions

    Maintenance 79 other maintenance actions transferring the memory unit to a new drive module when a drive module is replaced, the parameter settings can be retained by transferring the memory unit from the defective drive module to the new module. Warning! Do not remove or insert a memory unit when t...

  • Page 80

    Maintenance 80

  • Page 81: Technical Data

    Technical data 81 technical data what this chapter contains this chapter contains the technical specifications of the drive, e.G. The ratings, sizes and technical requirements, and provisions for fulfilling the requirements for ce and other markings. Ratings 400 v ac supply the nominal ratings for t...

  • Page 82

    Technical data 82 derating the continuous output currents stated above must be derated if any of the following conditions apply: • the ambient temperature exceeds +40 °c (+104°f) • the drive is installed higher than 1000 m above sea level. Note: the final derating factor is a multiplication of all a...

  • Page 83: Dimensions, Weights, Noise

    Technical data 83 dimensions, weights, noise see also the chapter dimension drawings . Cooling characteristics supply cable fuses fuses for short circuit protection of the supply cable are listed below. The fuses also protect the adjoining equipment of the drive in case of a short circuit. The opera...

  • Page 84: Ac Input (Supply) Connection

    Technical data 84 ac input (supply) connection voltage (u 1 ) 380 … 500 v ac +10%/-15%, 3-phase frequency 50 … 60 hz ±5% network type grounded (tn, tt) or ungrounded (it). Note: connection to an ungrounded (it) or corner-grounded delta network is not allowed at altitudes of 2000 m (6600 ft) or highe...

  • Page 85

    Technical data 85 digital inputs di1…di6 (xdi:1 … xdi:6) connector pitch 3.5 mm, wire size 1.5 mm 2 24 v logic levels: “0” 15 v r in : 2.0 kohm input type: npn/pnp (di1…di5), npn (di6) filtering: 0.25 ms min di6 (xdi:6) can alternatively be used as an input for 1…3 ptc thermistors. “0” > 4 kohm, “1”...

  • Page 86: Efficiency

    Technical data 86 isolation and grounding diagram efficiency approximately 98% at nominal power level cooling method forced air cooling (internal fan, flow direction from bottom to top). On/off control to have cooling only, when drive is running. Free space around the unit see chapter planning the c...

  • Page 87: Ambient Conditions

    Technical data 87 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 0...

  • Page 88: Materials

    Technical data 88 materials drive enclosure • jcu control unit housing: pc/abs, colour ncs 1502-y (ral 9002 / pms 420 c) • sheet metal parts: hot-dip zinc-coated steel. Front cover painted on the outside, colour ncs 1502-y (ral 9002 / pms 420 c) • heatsink: extruded aluminium alsi. Packaging cardboa...

  • Page 89: Ce Marking

    Technical data 89 ce marking a ce mark is attached to the drive to verify that the drive 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). Compliance with the european low voltage...

  • Page 90: C-Tick Marking

    Technical data 90 warning! The drive may cause radio interference if used in a residential or domestic environment. The user is required to take measures to prevent interference, in addition to the requirements for ce compliance listed above, if necessary. Compliance with en 61800-3 (2004), category...

  • Page 91: Ul Marking

    Technical data 91 ul marking see the type designation label for the valid markings of your drive. Ul checklist input power connection – see section ac input (supply) connection on page 84 . Disconnecting device (disconnecting means) – see section supply disconnecting device on page 36 . Ambient cond...

  • Page 92

    Technical data 92.

  • Page 93: Dimension Drawings

    Dimension drawings 93 dimension drawings what this chapter contains dimension drawings of the drive modules (frame sizes e0 and e) are shown below..

  • Page 94: Drive Module, Frame Size E0

    Dimension drawings 94 drive module, frame size e0

  • Page 95: Drive Module, Frame Size E

    Dimension drawings 95 drive module, frame size e.

  • Page 96

    Dimension drawings 96.

  • Page 97: Resistor Braking

    Resistor braking 97 resistor braking what this chapter contains this chapter describes how to select, protect and wire braking choppers and resistors. The chapter also contains the technical data. Braking choppers and resistors with the drive braking choppers braking chopper is available as an optio...

  • Page 98

    Resistor braking 98 • the braking energy must not exceed the energy dissipation capacity of the selected resistor • it is highly recommended that the resistor be protected from thermal overload; see the section contactor protection of drive below. Chopper data / resistor selection table the ratings ...

  • Page 99

    Resistor braking 99 resistor installation and wiring all resistors must be installed outside the drive module in a place where they are cooled sufficiently, do not block the airflow to other equipment, or dissipate hot air into the air inlets of other equipment. Warning! The materials near the braki...

  • Page 100

    Resistor braking 100 braking circuit commissioning for more information, see the appropriate firmware manual. • enable the braking chopper function. Please note that a braking resistor must be connected when the chopper is enabled • switch off the overvoltage control of the drive • adjust any other ...

  • Page 101: What This Chapter Contains

    Du/dt and common mode filtering 101 du/dt and common mode filtering what this chapter contains this chapter describes how to select du/dt and common mode filtering for the acs850-04. The chapter also contains the relevant technical data. When is du/dt or common mode filtering required? The output of...

  • Page 102: Filter Types

    Du/dt and common mode filtering 102 du/dt filters are optional accessories and to be ordered separately. For more information on common mode filtering, contact your local abb representative. Contact the motor manufacturer for information on the motor construction. Filter types du/dt filters * three ...

  • Page 103: Technical Data

    Du/dt and common mode filtering 103 technical data du/dt filters dimensions and weights * dimensions given are per phase degree of protection ip00 common mode filters contact your local abb representative. Installation follow the instructions included with the filters. Filter type height mm (inches)...

  • Page 104

    Du/dt and common mode filtering 104.

  • Page 106

    3aua00 000 454 87 rev b / en effective: 20 09- 07 -2 0 abb oy ac drives p.O. Box 184 fi-00381 helsinki finland telephone +358 10 22 11 fax +358 10 22 22681 internet www.Abb.Com abb inc. Automation technologies drives & motors 16250 west glendale drive new berlin, wi 53151 usa telephone 262 785-3200 ...