ABB ACQ810 Hardware Manual 0-45kW

ABB industrial drives

Hardware manual

ACQ810-04 drive modules (1.1…45 kW, 1…60 hp)

List of related manuals

Drive hardware manuals and guides

ACQ810-04 drive modules (1.1…45 kW, 1…60 hp) hardware manual

Code (English)

3AUA0000055160

1)

Drive firmware manuals and guides

ACQ810-04 drive modules start-up guide

ACQ810 standard pump control program firmware manual

3AUA0000055159

3AUA0000055144

2)

1)

Option manuals and guides

ACS-CP-U control panel IP54 mounting platform kit

(+J410) installation guide

Manuals and quick guides for I/O extension modules, fieldbus adapters, etc.

3AUA0000049072

2)

2)

1)

Delivered in PDF format on a manuals CD with the drive module.

2)

Delivered as a printed copy with the drive or optional equipment.

All manuals are available in PDF format on the Internet. See section

Document library on the Internet

on the inside of the back cover.

Hardware manual

ACQ810-04 drive modules (1.1…45 kW,

1…60 hp)

Table of contents

1. Safety instructions

5. Mechanical installation

7. Electrical installation

© 2009 ABB Oy. All Rights Reserved.

3AUA0000055160 Rev A

EN

EFFECTIVE: 2009-09-18

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 equipment. Read the safety instructions before you work on the unit.

Use of warnings and notes

There are four types of safety instructions used in this manual:

Dangerous voltage warning warns of high voltage which can cause physical injury and/or damage to the equipment.

General warning warns about conditions, other than those caused by electricity, which can result in physical injury and/or damage to the equipment.

Electrostatic discharge warning warns of electrostatic discharge which can damage the equipment.

Hot surface warning warns of component surfaces that may become hot enough to cause burns if touched.

6 Safety instructions

Installation and maintenance work

These warnings are intended for all who work on the drive, motor cable or motor.

WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment.

Only qualified electricians are allowed to install and maintain the drive.

•

Never work on the drive, the motor cable or the motor when input power is applied. After disconnecting the input power, always wait for 5 minutes to let the intermediate circuit capacitors discharge before you start working on the drive, the motor or the motor cable.

Always ensure by measuring with a multimeter (impedance at least 1 Mohm) that:

1. There is no voltage between the drive input phases U1, V1 and W1 and the ground.

2. There is no voltage between terminals UDC+ and UDC– and the ground.

3. There is no voltage between terminals R+ and R– and the ground.

•

Do not work on the control cables when power is applied to the drive or to the external control circuits. Externally supplied control circuits may carry dangerous voltages even when the input power of the drive is switched off.

•

Do not make any insulation or voltage withstand tests on the drive.

•

If a drive whose varistors or internal EMC filters are not disconnected is installed on an IT power system (an ungrounded power system or a high resistance grounded [over 30 ohms] power system), the drive will be connected to earth potential through the varistors/ filters. This may cause danger or damage the drive.

•

If a drive whose varistors or internal EMC filter are not disconnected is installed on a corner-grounded TN system, the drive will be damaged.

Notes:

•

Even when the motor is stopped, dangerous voltages are present at the power circuit terminals U1, V1, W1 and U2, V2, W2, and UDC+, UDC–, R+, R–.

•

Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V) may be present on the terminals of the relay outputs of the drive.

•

The drive supports the Safe torque off function. See page

40

.


•

The drive is not field repairable. 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 the drive during the installation.

Electrically conductive dust inside the drive may cause damage or lead to malfunction.

Safety instructions 7

•

Ensure sufficient cooling.

WARNING! The printed circuit boards contain components sensitive to electrostatic discharge. Wear a grounding wrist band when handling the boards. Do not touch the boards unnecessarily.

Start-up and operation

These warnings are intended for all who plan the operation of the drive, start up or operate the drive.


•

Before adjusting the drive and putting it into service, make sure that the motor and all driven equipment are suitable for operation throughout the speed range provided by the drive. The drive can be adjusted to operate the motor at speeds above and below the speed provided by connecting the motor directly to the power line.

•

Do not activate automatic fault reset functions if dangerous situations can occur. When activated, these functions will reset the drive and resume operation after a fault.

•

Do not control the motor with an AC contactor or disconnecting device (disconnecting means); instead, use the control panel or external commands via the I/O board of the drive or a fieldbus adapter. The maximum allowed number of charging cycles of the DC capacitors (i.e. power-ups by applying power) is one per two minutes. The maximum total number of chargings is 100000 for frame sizes A and B, 50000 for frame sizes C and D.

Notes:

•

If an external source for start command is selected and it is ON, the drive will start immediately after an input voltage break or a fault reset unless the drive is configured for

3-wire (pulse) start/stop.

•

When the control location is not set to local, the stop key on the control panel will not stop the drive.

WARNING! The surfaces of drive system components (such as the mains choke) may become hot when the system is in use.

8 Safety instructions

Table of contents 9

Table of contents

List of related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1. Safety instructions

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Start-up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2. About this manual

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Categorization according to the frame size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Categorization according to the + code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Installation and commissioning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3. Operation principle and hardware description


The ACQ810-04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Main circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Power connections and control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Type designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4. Planning the cabinet assembly


Cabinet construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Disposition of the devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Grounding of mounting structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Planning the fastening of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Main dimensions and free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Cooling and degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Preventing the recirculation of hot air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Cabinet heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5. Mechanical installation

Contents of the package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Delivery check and drive module identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

10 Table of contents

Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Direct wall mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

DIN rail mounting (Frames A and B only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Mains choke installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

EMC filter installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6. Planning the electrical installation


Motor selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Supply connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Other regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Thermal overload and short circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Thermal overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Protection against short-circuit in motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Protection against short-circuit in the supply cable or the drive . . . . . . . . . . . . . . . . . . . . 38

Motor thermal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Ground fault protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Emergency stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Safe torque off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Implementing a bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Protecting the relay output contacts and attenuating disturbances in case of inductive loads 44

Considering the PELV requirements at sites above 2000 m (6562 ft) . . . . . . . . . . . . . . . . . . 44

Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Connection of a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

7. Electrical installation


Removing the cover assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Supply cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Power cable connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Power cable connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Installation of optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61


Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Control connections to the JCU Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Grounding and routing the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

8. Installation checklist

Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

9. Maintenance


Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Fan replacement (Frames A and B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Fan replacement (Frames C and D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Other maintenance actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Transferring the memory unit to a new drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

10. Technical data


Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Cooling characteristics, noise levels, weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Supply cable fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Low harmonic filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

400 V / 50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

460 V / 60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

AC input (supply) connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

JCU Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Compliance with the Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

C-Tick marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92


Patent protection in the US . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

11. Mains chokes


When is a mains choke required? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Installation guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

12. EMC filters


When is an EMC filter required? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

JFI-A1/JFI-B1 (Frame A/B, category C3) installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Installation guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Mounting procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

JFI-0x (Frames A…D, category C2) installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Installation guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

13. du/dt and common mode filtering

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

When is du/dt or common mode filtering required? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Filter types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 du/dt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Common mode filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 du/dt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Common mode filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

14. Dimension drawings

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Frame size A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Frame size B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Frame size C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Frame size D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Mains chokes (type CHK-0x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

EMC filters (type JFI-x1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

JFI-A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

JFI-B1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

EMC filters (type JFI-0x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Further information

Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121


Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121


About this manual 15

About this manual


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 other manuals.

Compatibility

The manual is compatible with ACQ810-04 drive modules of frame sizes A to D.

Intended audience

This manual is intended for people who plan the installation, install, commission, use and service the drive. Read the manual before working on the drive. The reader is expected to know the fundamentals of electricity, wiring, electrical components and electrical schematic symbols.

This manual is written for readers worldwide. Both SI and imperial units are shown wherever appropriate.

Categorization according to the frame size

Some instructions, technical data and dimensional drawings which concern only certain frame sizes are marked with the symbol of the frame size A, B, C or D. The frame size is marked on the drive designation label. The frame size of each drive type

is also indicated in the rating tables in chapter

Technical data

.

16 About this manual

Categorization according to the + code

The instructions, technical data and dimensional drawings which concern only certain optional selections are marked with + codes, e.g. +L500. The options included in the drive can be identified from the + codes visible on the type designation label of the

drive. The + code selections are listed in chapter

Operation principle and hardware description

under

Type designation

.

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 the drive and refers to chapters/sections in this manual and other manuals for particular tasks.

Operation principle and hardware description

describes the drive module.

Planning the cabinet assembly

guides in planning the installation of the drive module into a user-defined cabinet.

Mechanical installation

instructs how to place and mount the drive.

Planning the electrical installation

instructs on the motor and cable selection, the protections and the cable routing.

Electrical installation

instructs on how to wire the drive.

Installation checklist

contains a list for checking the mechanical and electrical installation of the drive.

Maintenance

lists periodic maintenance actions along with work instructions.

Technical data

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.

Mains chokes

details the optional mains chokes available for the drive.

EMC filters

details the EMC filtering options for the drive.

du/dt and common mode filtering

lists the du/dt and common mode filtering options available for the drive.

Dimension drawings

contains the dimensional drawings of the drive and connected equipment.


Installation and commissioning flowchart

Task See

Identify the frame size of your drive: A, B, C or D. Drive designation label or

Technical data

:

Ratings

(page

77

)

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.


(page

27

)


(page

37

)

Technical data

(page

77

)

Option manual (if optional equipment is included)

Unpack and check the units.

Check that all necessary optional modules and equipment are present and correct.

Only intact units may be started up.


:

Contents of the package

(page

33

)

If the converter has been non-operational for more than one year, the converter DC link capacitors need to be reformed. Ask

ABB for more information.

Check the installation site.


:

Before installation

(page

35

)

Technical data

(page

77

)

Install the drive in a cabinet.

Route the cables.


:

Installation procedure

(page

36

)


:

Routing

the cables (page

46

)

Check the insulation of the supply cable, the motor and the motor cable.


:

Checking the

insulation of the assembly

(page

51

)


Task See

If the drive is about to be connected to an IT

(ungrounded) system, disconnect the internal varistors and EMC filters. Also note that using an

EMC filter is not allowed in an IT (ungrounded) system.


:

Installation and maintenance work

(page

6

)


:

Power cable connection

(page

52

)

Connect the power cables.

Connect the control and the auxiliary control cables.


:


: (page

52

) and

Connecting the control cables

: (page

62

)

For optional equipment:

Mains chokes

(page

95

)

EMC filters

(page

99

)


(page

105

)

Manuals for any optional equipment

Check the installation.

Commission the drive.

Installation checklist

(page

69

Appropriate Firmware manual

Operating of the drive: start, stop, speed control etc.

Appropriate Firmware manual

)


Terms and abbreviations

Term/Abbreviation

CHK-xx

EMC

FIO-11

FIO-21

FIO-31

FDNA-0x

FENA-0x

FLON-0x

FPBA-0x

Frame (size)

FSCA-0x

IGBT

I/O

JCU

JFI-xx

JMU

RFI

Explanation

Series of optional mains chokes for the ACQ810.

Electromagnetic Compatibility.

Optional analog I/O extension for the ACQ810.

Optional analog/digital I/O extension for the ACQ810.

Optional digital I/O extension for the ACQ810.

Optional DeviceNet adapter for the ACQ810.

Optional Ethernet/IP adapter for the ACQ810.

Optional L

ON

W

ORKS

®

adapter for the ACQ810.

Optional PROFIBUS DP adapter for the ACQ810.

Size of the drive module. This manual deals with ACQ810-04 frames A, B, C and D. To determine the frame size of a drive module, refer to the drive designation label attached to the drive, or the rating tables in chapter

Technical data

.

Optional Modbus adapter for the ACQ810.

Insulated Gate Bipolar Transistor; a voltage-controlled semiconductor type widely used in inverters due to their easy controllability and high switching frequency.

Input/Output.

The control unit of the drive module. The JCU is installed on top of the power unit. The external I/O control signals are connected to the JCU, or optional I/O extensions mounted on it.

Series of optional EMC filters for the ACQ810.

The memory unit attached to the control unit of the drive.

Radio-frequency interference.


Operation principle and hardware description 21

Operation principle and hardware description


This chapter describes the operating principle and construction of the ACQ810-04 drive module in short.

The ACQ810-04

The ACQ810-04 is an air-cooled IP20 drive module for controlling AC motors for water and waste water applications. It is to be installed into a cabinet by the customer.

It is available in several frame sizes depending on output power. All frame sizes use the same control unit (type JCU).

22 Operation principle and hardware description

Layout

Drive module, frame size A

Motor connections

DC connection

AC supply connection

JCU Control Unit

JCU Control Unit with cover assembly removed

External 24 V power input

Slot 1 for optional

I/O extension or fieldbus adapter

Slot 2 for optional fieldbus adapter

Relay outputs

+24 V output

Digital inputs

Digital inputs/ outputs

Reference voltage and analog inputs

Analog outputs

Drive-to-drive link

Safe torque off connection

Control panel/PC connection

Memory unit

(JMU) connection


Operation principle

Main circuit

The main circuit of the drive module is shown below.

Inverter

AC supply

UDC+ UDCU1 V1 W1

+

~

=

–

ACQ810-04

CHK-xx mains choke (see chapter

Mains chokes

on page

95

)

JFI-xx EMC filter (see chapter

EMC filters

on page

99

)

Rectifier

Capacitor bank

U2

=

~

V2 W2 RR+

NOCHxxxx-xx du/dt filter (see chapter

du/ dt and common mode filtering

on page

105

)

Motor output

Component Description

Capacitor bank Energy storage which stabilizes the intermediate circuit DC voltage.

du/dt filter

Inverter

See page

105

.

Mains choke

EMC filter

Rectifier

Converts the DC voltage to AC voltage and vice versa. The motor is controlled by switching the IGBTs of the inverter.

See page

95

.

See page

99

.

Converts the three-phase AC voltage to DC voltage.

Motor control

The motor control is based on direct torque control. Two phase currents and DC link voltage are measured and used for the control. The third phase current is measured for earth fault protection.


Power connections and control interfaces

The diagram shows the power connections and control interfaces of the drive.

Slot 1

(I/O extension or fieldbus adapter)

FIO-11 (Analog I/O extension)

FIO-21 (Digital/Analog I/O extension)

FIO-31 (Digital I/O extension)

Slot 2

(Fieldbus adapter)

FDNA-0x (DeviceNet)

FENA-0x (Ethernet/IP)

FLON-01 (L

ON

W

ORKS®

)

FSCA-01 (Modbus)

FPBA-0x (PROFIBUS

DP)

Note: If no I/O extension is used, the fieldbus adapter can be connected to Slot 1.

Fxx

Fxxx

Slot 1

Slot 2

Control unit (JCU)

Memory unit

(see page

75

)

Control panel or PC

External power input XPOW

Relay outputs

1)

XRO1…2

+24 V output

Digital inputs

Digital inputs/ outputs

1)

1)

Reference voltage and analog inputs

1)

Analog outputs

1)

Drive-to-drive link

Safe torque off

XD24

XDI

XDIO

XAI

XAO

XD2D

XSTO

For more information on these connections, see page

62

. For specifications, see page

85

.

1)

Programmable

3-phase power supply

PE

L1

L2

L3

PE

U1

V1

W1

Power unit

R-

U2

V2

UDC+

R+ UDC-

W2

M

3 ~

AC motor


Type designation

The type designation contains information on the specifications and configuration of the drive. The first digits from left express the basic configuration (e.g. ACQ810-04-

14A4-4). The optional selections are given thereafter, preceded by + signs (e.g.

+L500). The main selections are described below. Not all selections are necessarily available for all types; refer to ACQ810 Ordering Information, available on request.

See also section

Delivery check and drive module identification

on page

35.

Selection Alternatives

Product series ACQ810 product series

Type

04 Drive module. When no options are selected: IP20 (UL Open type), control panel, EMC filter for Category C3, in-built choke in frame sizes

C and D, boards with coating, Safe torque off function, ACQ810 standard pump control program, Start-up guide and CD containing all manuals

Size

Refer to

Technical data : Ratings .

Voltage range

4 380…480 V AC

+ options

Filters

Control panel and control unit mechanics

Fieldbus

I/O extensions and feedback interfaces

E… +0E200: No EMC filter

J… +0J400: No control panel or panel holder

+J410: Control panel with door mounting platform kit including IP54 kit and 3 m cable

+0C168: No control unit cover, no control panel

K...

+K451: FDNA-01 DeviceNet adapter

+K454: FPBA-01 PROFIBUS DP adapter

+K466: FENA-01 Ethernet/IP adapter

+K458: FSCA-01 Modbus adapter

+K452: FLON-01 L

ON

W

ORKS

®

adapter

L...

+L500: FIO-11 analog I/O extension

+L519: FIO-21 analog/digital I/O extension

+L511: FIO-31 digital I/O extension (4 relays)

00588241


Planning the cabinet assembly 27

Planning the cabinet assembly


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: The installation examples in this manual are provided only to help the installer in designing the installation. Please note that the installation must, however,

always be designed and made according to applicable local laws and

regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations.

Cabinet construction

The cabinet frame must be sturdy enough to carry the weight of the drive components, control circuitry and other equipment installed in it.

The cabinet must protect the drive module against contact and meet the

requirements for dust and humidity (see the chapter

Technical data

).

Disposition of the devices

For easy installation and maintenance, a spacious layout is recommended. Sufficient cooling air flow, obligatory clearances, cables and cable support structures all require space.

For a layout example, see section

Cooling and degrees of protection

below.

28 Planning the cabinet assembly

Grounding of mounting structures

Make sure all cross-members or shelves on which drive system components are mounted are properly grounded and the connecting surfaces left unpainted.

Note: Ensure that the components are properly grounded through their fastening points to the installation base.

Note: It is recommended that the EMC filter (if present) and the drive module be mounted on the same mounting plate.

Planning the fastening of the cabinet

WARNING! Do not fasten the cabinet by electric welding. ABB does not assume any liability for damages caused by electric welding as the welding circuit may damage electronic circuits in the cabinet.


Main dimensions and free space requirements

The modules can be installed side by side. The dimensions of the drive modules as well as free space requirements are presented below. For more details, refer to

chapter


.

Frame D Frame C Frame B Frame A


Note: EMC filters of type JFI-x1 mounted directly above the drive module do not increase the free space requirements. (For EMC filters of type JFI-0x, see the dimension drawing of the filters on page

119

.)

200 mm [7.9”]

300 mm [12”]

The temperature of the cooling air entering the unit must not exceed the maximum allowed ambient temperature (see

Ambient conditions

in the chapter

Technical data

).

Consider this when installing heat-generating components (such as other drives and mains chokes) nearby.

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

• protect against contact

• prevent water splashes from entering the cabinet.

The drawing below shows two typical cabinet cooling solutions. The air inlet is at the bottom of the cabinet, while the outlet is at the top, either on the upper part of the door or on the roof.


Air outlet

Air inlet

Arrange the cooling of the modules so that the requirements given in chapter

Technical data

are met:

• cooling air flow

Note: The values in

Technical data

apply to continuous nominal load. If the load is

less than nominal, less cooling air is required.

• allowed ambient temperature.

Make sure the air inlets and outlets are sufficient in size. Please note that in addition to the power loss of the drive module, the heat dissipated by cables and other additional equipment must also be ventilated.

The internal cooling fans of the modules are usually sufficient to keep the component temperatures low enough in IP22 cabinets.

In IP54 cabinets, thick filter mats are used to prevent water splashes from entering the cabinet. This entails the installation of additional cooling equipment, such as a hot air exhaust fan.

The installation site must be sufficiently ventilated.


Preventing the recirculation of hot air

Cabinet (side view)

HOT

AREA

Main airflow out

Air baffle plates

COOL AREA

Main airflow in

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 flow at the air inlet and outlet

• air inlet and outlet at different sides of the cabinet

• cool air inlet in the lower part of the front door and an extra exhaust fan on the roof of the cabinet.

Inside the cabinet

Prevent hot air circulation inside the cabinet with leak-proof air baffle plates. No gaskets are usually required.

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 provided by its manufacturer.

Mechanical installation 33

Mechanical installation

Contents of the package

The drive is delivered in a cardboard box. To open, remove any banding and lift the top off the box.

34 Mechanical installation

The box contains:

• ACQ810-04 drive module, with factory-installed options

• three cable clamp plates (two for power cabling, one for control cabling) with screws

• screw-type terminal blocks to be attached to the headers on the JCU Control Unit and the power unit

• category C3 EMC filter (external in frame sizes A and B, internal in frame sizes C and D)

• control panel mounting kit (+J410) if ordered

• Start-up guide and manuals CD.

EMC filter, control panel mounting kit

(Underneath the drive module – lift out the module and open left-hand side flap to access)

ACQ810-04 drive module

Compartments for cable clamp plates

Compartment for terminal blocks and manuals

Mechanical installation 35

Delivery check and drive module identification

Check that there are no signs of damage. Before attempting installation and operation, check the information on the type designation label of the drive module to verify that the unit is of the correct type. The label is located on the left-hand side of the drive module.

Type code + options

(see page

25

)

Compliance markings

Frame size Ratings Serial number

The first digit of the serial number refers to the manufacturing plant. The 2nd and 3rd digit indicate the year of manufacture, while the 4th and 5th digits indicate the week.

Digits 6 to 10 are a running integer starting every week at 00001.

Before installation

See

Technical data

for the allowed operation conditions of the drive. Refer to


for frame details.

The wall the drive is to be mounted on must be as even as possible, of nonflammable material and strong enough to carry the weight of the drive. The floor/ material below the drive must be non-flammable.

36 Mechanical installation

Installation procedure

Direct wall mounting

1. Mark the locations for the four holes. The mounting points are shown in


.

2. Fix the screws or bolts to the marked locations.

3. Position the drive onto the screws on the wall. Note: Only lift the drive by its chassis.

4. Tighten the screws.

DIN rail mounting (Frames A and B only)

1. Click the drive to the rail as shown in Figure a below. To detach the drive, press the release lever on top of the drive as shown in Figure b.

2. Fasten the lower edge of the drive to the mounting base through the two fastening points.

a

1

b

2

Mains choke installation

See the chapter

Mains chokes

on page

95

.

EMC filter installation

See the chapter

EMC filters

on page

99

.

Planning the electrical installation 37

Planning the electrical installation


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 not followed, the drive may experience problems that the warranty does not cover.

Note: The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations.

Motor selection

Select the (3-phase AC induction) motor according to the rating table in the chapter

Technical data

. The table lists the typical motor power for each drive type. See also requirements table on page

106

.

Supply connection

Use a fixed connection to the AC power line.

WARNING! As the leakage current of the device typically exceeds 3.5 mA, a fixed installation is required according to IEC 61800-5-1.

38 Planning the electrical installation

Supply disconnecting device

Install a hand-operated input disconnecting device (disconnecting means) between the AC power source and the drive. The disconnecting device must be of a type that can be locked to the open position for installation and maintenance work.

Europe

If the drive is used in an application which must meet the European Union Machinery

Directive according to standard EN 60204-1 Safety of Machinery, the disconnecting device must be one of the following types:

• a switch-disconnector of utilization category AC-23B (EN 60947-3)

• a disconnector that has an auxiliary contact that in all cases causes switching devices to break the load circuit before the opening of the main contacts of the disconnector (EN 60947-3)

• a circuit breaker suitable for isolation in accordance with EN 60947-2.

Other regions

The disconnecting means must conform to the applicable safety regulations.

Thermal overload and short circuit protection

Thermal overload protection

The drive protects itself and the input and motor cables against thermal overload when the cables are dimensioned according to the nominal current of the drive. No additional thermal protection devices are needed.

WARNING! If the drive is connected to multiple motors, a separate thermal overload switch or a circuit breaker must be used for protecting each cable and motor. These devices may require a separate fuse to cut off the shortcircuit current.

Protection against short-circuit in motor cable

The drive protects the motor cable and the motor in a short-circuit situation when the motor cable is dimensioned according to the nominal current of the drive. No additional protection devices are needed.

Protection against short-circuit in the supply cable or the drive

Protect the supply cable with fuses or circuit breakers. Fuse recommendations are given in the chapter

Technical data

. When placed at the distribution board, standard

IEC gG fuses or UL type T fuses will protect the input cable in short-circuit situations,


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

Check that the operating time of the fuse is below 0.5 seconds. The operating time depends on the type, the supply network impedance, and the cross-sectional area, material and length of the supply cable. US fuses must be of the “non-time delay” type.

Circuit breakers

The protective characteristics of circuit breakers depend on the supply voltage as well as the type and construction of the breakers. There are also limitations pertaining to the short-circuit capacity of the supply network. Your local ABB representative can help you in selecting the breaker type when the supply network characteristics are known.

Motor thermal protection

According to regulations, the motor must be protected against thermal overload and the current must be switched off when overloading is detected. The drive includes a motor thermal protection function that protects the motor and switches off the current when necessary. Depending on a drive parameter value, the function either monitors a calculated temperature value (based on a motor thermal model) or an actual temperature indication given by motor temperature sensors. The user can tune the thermal model further by feeding in additional motor and load data.

PTC sensors can be connected directly to the ACQ810-04. See page

65

in this

manual, and the appropriate Firmware manual for the parameter settings concerning motor thermal protection.

Ground fault protection

The drive is equipped with an internal ground fault protective function to protect the unit against ground faults in the motor and the motor cable. This is not a personal safety or a fire protection feature. The ground fault protective function can be disabled with a parameter, refer to the appropriate Firmware manual.

The optional EMC filter includes capacitors connected between the main circuit and the frame. These capacitors and long motor cables increase the ground leakage current and may cause fault current circuit breakers to function.

Emergency stop devices

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 drive does not generate an emergency stop of the motor or separate the drive from dangerous potential.

Safe torque off

The drive supports the Safe torque off function according to standards

EN 61800-5-2:2007; 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 semiconductors of the drive output stage, thus preventing the inverter from generating the voltage required to rotate the motor (see diagram below). By using this function, short-time operations (like cleaning) and/or maintenance work on non-electrical parts of the machinery can be performed without switching off the power supply to the drive.

Control circuit

+24 V

Safe torque off connection on

JCU

Drive

XSTO:1

XSTO:2

XSTO:3

XSTO:4

UDC+

Output stage

(1 phase shown)

UDC-

Activation switch

U2/V2/W2

Notes:

• The contacts of the activation switch must open/close within 200 ms of each other.

• The maximum cable length between the drive and the activation switch is

25 m (82 ft)

WARNING! The Safe torque off function does not disconnect the voltage of the main and auxiliary circuits from the drive. Therefore maintenance work on electrical parts of the drive or the motor can only be carried out after isolating the drive system from the main supply.


Note: If a running drive is stopped by using the Safe torque off function, the drive will cut off the motor supply voltage and the motor will coast to stop.

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 rated for at least 70 °C (US: 75 °C [167 °F]) maximum permissible temperature of conductor in continuous use.

• The inductance and impedance of the PE conductor/cable (grounding wire) must be rated according to permissible touch voltage appearing under fault conditions

(so that the fault point voltage will not rise excessively when a ground fault occurs).

• 600 V AC cable is accepted for up to 500 V AC.

• Refer to the chapter

Technical data

for EMC requirements.

Symmetrical shielded motor cable must be used (see the figure below) to meet the

EMC requirements of the CE and C-tick marks.

A four-conductor system is allowed for input cabling, but shielded symmetrical cable is recommended. To operate as a protective conductor, the shield conductivity must be as follows when the protective conductor is made of the same metal as the phase conductors:

Cross-sectional area of one phase conductor (S)

S < 16 mm

2

16 mm

2

< S < 35 mm

2

35 mm

2

< S

Minimum cross-sectional area of protective conductor (S p

)

S

16 mm

2

S/2

Compared to a four-conductor system, the use of symmetrical shielded cable reduces electromagnetic emission of the whole drive system as well as motor bearing currents and wear.

The motor cable and its PE pigtail (twisted shield) should be kept as short as possible in order to reduce electromagnetic emission, as well as stray currents outside the cable and capacitive current.


Alternative power cable types

Power cable types that can be used with the drive are represented below.

Motor cable

(also recommended for supply cabling)

Symmetrical shielded cable: three phase conductors and a concentric or otherwise symmetrically constructed PE conductor, and a shield

Note: A separate PE conductor is required if the conductivity of the cable shield is not sufficient for the purpose. See section

General rules

above.

PE conductor and shield

Shield

PE

Shield

PE

Allowed for supply cabling

A four-conductor system: three phase conductors and a protective conductor.

Shield

PE PE

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 same metal.

To effectively suppress radiated and conducted radio-frequency emissions, the shield conductivity must be at least 1/10 of the phase conductor conductivity. The requirements are easily met with a copper or aluminium shield. The minimum requirement of the motor cable shield of the drive is shown below. It consists of a concentric layer of copper wires with an open helix of copper tape. The better and tighter the shield, the lower the emission level and the bearing currents.

Helix of copper tape

Insulation jacket Copper wire screen

Inner insulation

Cable core


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 the interlocking that the contactors cannot be closed simultaneously.

Follow this control sequence:

1. Stop the drive.

2. Stop the motor.

3. Open the contactor between the drive and the motor.

4. Close the contactor between the motor and the power line.

An example bypass connection is shown below.

Switch

S11

S40

S41

S42

Description

Drive main contactor on/off control

Motor power supply selection (drive or direct on line)

Start when motor is connected on line

Stop when motor is connected direct on line

WARNING! Never connect the supply power to the drive output terminals U2,

V2 and W2. Line voltage applied to the output can result in permanent damage to the unit.


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 outputs on the drive are protected with varistors (250 V) against overvoltage peaks. In addition, it is highly recommended to equip inductive loads with noise attenuating circuits (varistors, RC filters [AC] or diodes [DC]) in order to minimize the electromagnetic emissions at switch-off. If not suppressed, the disturbances may connect capacitively or inductively to other conductors in the control cable and form a risk of malfunction in other parts of the system.

Install the protective component as close to the inductive load as possible, not at the relay output.

Varistor

230 V AC

Relay output

RC filter

230 V AC

Relay output

Diode

24 V DC

Relay output

Considering the PELV requirements at sites above 2000 m

(6562 ft)

WARNING! Do not use a voltage greater than 48 V for the relay outputs of drive module at installation sites above 2000 meters (6562 feet). Use of a voltage greater than 48 V may damage the drive and can cause malfanction and physical injury. The Protective Extra Low Voltage (PELV) requirements are not fulfilled if a relay output is used with a voltage greater than 48 V.


Selecting the control cables

It is recommended that all control cables be shielded.

Double-shielded twisted pair cable is recommended for analog signals. For pulse encoder cabling, follow the instructions given by the encoder manufacturer. Use one individually-shielded pair for each signal. Do not use a common return for different analog signals.

Double-shielded cable is the best alternative for low-voltage digital signals but singleshielded twisted multipair cable (Figure b) is also usable.

a

Double-shielded twisted pair cable b

Single-shielded twisted multipair cable

Run analog and digital signals in separate cables.

Relay-controlled signals, providing their voltage does not exceed 48 V, can be run in the same cables as digital input signals. It is recommended that the relay-controlled signals be run as twisted pairs.

Never mix 24 V DC and 115/230 V AC signals in the same cable.

Relay cable

The cable type with braided metallic screen (e.g. ÖLFLEX by Lapp Kabel, Germany) has been tested and approved by ABB.

Control panel cable

The cable connecting the control panel to the drive must not exceed 3 metres in length. The cable type tested and approved by ABB is used in control panel option kits.

Connection of a motor temperature sensor to the drive I/O

See page

65

.


Routing the cables

Route the motor cable away from other cable routes. Motor cables of several drives can be run in parallel installed next to each other. It is recommended that the motor cable, input power cable and control cables be installed on separate trays. Avoid long parallel runs of motor cables with other cables in order to decrease electromagnetic interference caused by the rapid changes in the drive output voltage.

Where control cables must cross power cables make sure they are arranged at an angle as near to 90 degrees as possible. Do not run extra cables through the drive.

The cable trays must have good electrical bonding to each other and to the grounding electrodes. Aluminium tray systems can be used to improve local equalizing of potential.

A diagram of the cable routing is below.

Supply cable min 200 mm (8”)

90°

Supply cable

Motor cable min 300 mm (12”)

Drive

Control cables

90° min 500 mm (20”)

Motor cable

Control cable ducts

24 V 230 V


24 V 230 V

Not allowed unless the 24 V cable is insulated for 230 V or insulated with an insulation sleeving for 230 V.

Lead 24 V and 230 V control cables in separate ducts inside the cabinet.


Electrical installation 49

Electrical installation


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


on the first pages of this

manual. Ignoring the safety instructions can cause injury or death.

Make sure that the drive is disconnected from the supply (input power) during installation. If the drive is already connected to the supply, wait for 5 minutes after disconnecting the input power.

Removing the cover assembly

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.

• Press the tab (1) slightly with a screwdriver.

• Slide the lower cover plate slightly downwards and pull it out (2).

• Disconnect the panel cable (3) if present.

• Remove the screw (4) at the top of the cover assembly.

• Carefully pull the lower part of the base outwards by the two tabs (5).

Refit the cover in reverse order to the above procedure.

50 Electrical installation

2

1

4

5

3


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 chassis at the factory.

Also, there are voltage-limiting circuits inside the drive which cut down the testing voltage automatically.

Supply cable

Check the insulation of the supply (input) cable according to local regulations before connecting to the drive.

Motor and motor cable

Check the insulation of the motor and motor cable as follows:

1. Check that the motor cable is connected to the motor, and 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 a measuring voltage of 500 V DC. The insulation resistance of an ABB motor must exceed 100 Mohm (reference value at

25 °C or 77 °F). For the insulation resistance of other motors, please consult the manufacturer’s instructions. Note: Moisture inside the motor casing will reduce the insulation resistance. If moisture is suspected, dry the motor and repeat the measurement.

ohm

U1

V1

M

3~

W1 PE


Power cable connection

Power cable connection diagram

For alternatives, see


:

Supply disconnecting device

(page

38

).

CHK-xx mains choke (optional). See the

chapter

Mains chokes

(page

95

).

JFI-xx EMC filter (optional). See the chapter

EMC filters

(page

99

).

The UDC+/UDC– connectors can be used for common DC configurations. See page

59

.

ACQ810-04

UDC+ UDC–

L1 L2 L3 (PE) (PE)

1) 2)

U1 V1 W1

PE

U2 V2 W2 R– R+ du/dt filter(s) (optional).

See the chapter


(page

105

).

3)

U1

V1

3

~

Motor

W1

PE

Notes:

• If shielded supply (input) cable is used, and the conductivity of the shield is not sufficient (see section

Selecting the power cables

on page

41

), use a cable with a ground conductor (1) or a separate PE cable (2).

• For motor cabling, use a separate ground cable (3) if the conductivity of the cable shield is not sufficient (see section


on page

41

) and the cable has no symmetrical ground conductors.


Procedure

Cabling drawings with tightening torques for each frame size are presented on pages

56

to

58

.

1. Frame sizes C and D only: Remove the two plastic connector covers at the top and bottom of the drive. Each cover is fastened with two screws.

2. On IT (ungrounded) systems and corner grounded TN systems, remove the following screws to disconnect the internal varistors and EMC filters:

• VAR (frames A and B, located close to the supply terminals)

• EMC, VAR1 and VAR2 (frames C and D, located on the front of the power unit).

WARNING! If a drive whose varistors/filters are not disconnected is installed on an IT system (an ungrounded power system or a high resistance grounded

[over 30 ohms] power system), the system will be connected to earth potential through the varistors/filters of the drive. This may cause danger or damage the drive.

If a drive whose varistors/filters are not disconnected is installed on a corner grounded TN system, the drive will be damaged.

3. Fasten the two cable clamp plates included to the drive (see page

55

), one at the

top, one at the bottom. The clamp plates are identical. Using the cable clamp plates as shown below will provide better EMC compliance, as well as act as a strain relief for the power cables.

4. Strip the power cables so that the shields are bare at the cable clamps.

5. Twist the ends of the cable shield wires into pigtails.

6. Strip the ends of the phase conductors.

7. Connect the phase conductors of the supply cable to the U1, V1 and W1 terminals of the drive.

Connect the phase conductors of the motor cable to the U2, V2 and W2 terminals.

With frame size C or D, attach the screw terminal lugs included to the conductors first. Crimp lugs can be used instead of the screw lugs.

8. Tighten the cable clamps onto the bare cable shields.

9. Crimp a cable lug onto each shield pigtail. Fasten the lugs to ground terminals.

Note: Try to work out a compromise between the length of the pigtail and the length of unshielded phase conductors as both should ideally be as short as possible.

10. Cover visible bare shield and pigtail with insulating tape.

11. With frame size C or D, cut suitable slots on the edges of the connector covers to accommodate the supply and motor cables. Refit the covers. (Tighten the screws to 3 N·m [25 lbf·in]).

12. Secure the cables outside the unit mechanically.


13. Ground the other end of the supply cable shield or PE conductor(s) at the distribution board. In case a mains choke and/or an EMC filter is installed, make sure the PE conductor is continuous from the distribution board to the drive.

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

360 degrees grounding

Conductive gaskets or ground the cable by twisting the shield so that the flattened shield is wider than 1/5 of its length.

a b b > 1/5 · a


Installation of power cable clamp plates

Two identical power cable clamp plates are included with the drive. The picture below depicts a frame size A drive; the installation is similar with other frame sizes.

Note: Pay attention to supporting the cables adequately within the installation enclosure especially if not using the cable clamps.

Frames A and B: 1.5 N·m (13 lbf·in)

Frames C and D: 3 N·m (25 lbf·in)

1.5 N·m (13 lbf·in)


Power cable connection – frame size A

Supply cable

Cable clamp on bare

shield 1.5 N·m (13 lbf·in)

Below cable clamp, cover bare shield with insulating tape

1.5 N·m (13 lbf·in)

0.5 … 0.6 N·m (4.4 … 5.3 lbf·in)

1.5 N·m (13 lbf·in)

Motor cable

0.5 … 0.6 N·m

(4.4 … 5.3 lbf·in)

Above cable clamp, cover bare shield with insulating tape




Power cable connection – frame size B

Supply cable

U1 V1 W1

Cable clamp on bare shield

1.5 N·m (13 lbf·in)


1.5 N·m (13 lbf·in)

1.2 … 1.5 N·m

(10.6 … 13.3 lbf·in)

1.5 N·m (13 lbf·in)

U2 V2 W2 RR+


Cable clamp on bare shield

1.5 N·m (13 lbf·in)

Motor cable


Power cable connection – frame sizes C and D (connector covers removed)

Supply cable




Frame C:

3 N·m (25 lbf·in)

Frame D:

18 N·m (160 lbf·in)

Screw lug detail

15 N·m (11 lbf·ft)

U1 V1 W1

U2 V2 W2 RR+

15 N·m (11 lbf·ft)

Direct lug connection

Instead of using the screw lugs included, the conductors of power cables can be connected to the drive terminals by removing the screw lugs and using crimp lugs.

3 N·m (25 lbf·in)

15 N·m (11 lbf·ft)

Frame C:

3 N·m

(25 lbf·in)

Frame D:

18 N·m

(160 lbf·in)

Motor cable

Cable clamp on

bare shield

1.5 N·m (13 lbf·ft)



DC connection

The UDC+ and UDC– terminals are intended for common DC configurations of a number of ACQ810 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 the power requirement. In case two or more drives are connected to the AC supply, each AC connection must be equipped with a mains choke to ensure even current distribution between the rectifiers. The diagram below shows two configuration examples.

AC supply

UDC+

UDC–

~

~

UDC+

UDC–

~

~

UDC+

UDC–

~

~

M

3~

M

3~

M

3~

AC supply

UDC+

UDC–

~

~

Mains chokes

UDC+

UDC–

~

~

UDC+

UDC–

~

~

M

3~

M

3~

M

3~


Each drive has an independent DC capacitor pre-charging circuit.

UDC+ UDCU1 V1 W1

+

~

=

–

Pre-charging circuit

=

~

U2 V2 W2

The ratings of the DC connection are given on page

84

.

Connecting a PC

Connect the PC to connector X7 on the control unit (see page

22

) or to the connector

in the control panel holder.


Installation of optional modules

Optional modules such as fieldbus adapters and I/O extensions ordered using option codes (see

Type designation

on page

25

) are pre-installed at the factory. Instructions

for installing additional modules into the slots on the JCU Control Unit (see page

24

for the available slots) are presented below.

Mechanical installation

• Remove the cover assembly from on the JCU Control Unit (refer to page

49

).

• Remove the protective cover (if present) from the connector of the slot.

• Insert the module carefully into its position on the drive.

• Fasten the screw.

Note: Correct installation of the screw is essential for fulfilling the EMC requirements and for proper operation of the module.

Electrical installation

See section

Grounding and routing the control cables

on page

67

. See the

appropriate option manual for specific installation and wiring instructions.


Connecting the control cables

Control connections to the JCU Control Unit

External power input

24 V DC, 1.6 A

Relay output RO1 [Ready]

250 V AC / 30 V DC

2 A

Relay output RO2 [Fault(-1)]

250 V AC / 30 V DC

2 A

+24 V DC*

Digital input ground

+24 V DC*

Digital input/output ground

Ground selection jumper

Digital input DI1 [Stop/Start]

Digital input DI2 [Constant speed 1]

Digital input DI3 [Reset]

Digital input DI4

Digital input DI5 [EXT1/EXT2 selection]

Start interlock (0 = Stop)

Digital input/output DIO1 [Output: Ready]

Digital input/output DIO2 [Output: Running]

Reference voltage (+)

Reference voltage (–)

Ground

Analog input AI1 (Current or voltage, selectable by jumper AI1) [Current]

[Speed reference 1]

Analog input AI2 (Current or voltage, selectable by jumper AI2) [Current]

[Process actual value 1]

AI1 current/voltage selection jumper

AI2 current/voltage selection jumper

Analog output AO1 [Current]

Analog output AO2 [Speed rpm]

Drive-to-drive link termination jumper

Drive-to-drive link.

Safe torque off. Both circuits must be closed for the drive to start.

Control panel connection

Memory unit connection

DI1

DI2

DI3

DI4

DI5

DIIL

DIO1

DIO2

+VREF

-VREF

AGND

AI1+

AI1-

AI2+

AI2-

+24VI

GND

NO

COM

NC

NO

COM

NC

+24VD

DIGND

+24VD

DIOGND

AO1+

AO1-

AO2+

AO2-

B

A

BGND

OUT1

OUT2

IN1

IN2

1

2

1

2

4

5

A

AI1

1

2

3

3

4

1

2

5

6

3

4

4

T

2

3

7

AI1

AI2

1

5

6

3

4

1

2

1

2

2

3

4

3

1

1

2

Notes: [Default setting with ACQ810 standard pump 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 the connectors and jumpers are given in the text; see also the chapter

Technical data

.

Wire sizes and tightening torques:

XPOW, XRO1, XRO2, XD24:

0.5 … 2.5 mm

2

(24…12 AWG)

Torque: 0.5 N·m (5 lbf·in)

XDI, XDIO, XAI, XAO, XD2D, XSTO:

0.5 … 1.5 mm

2

(28…14 AWG)

Torque: 0.3 N·m (3 lbf·in)


Order of terminal headers and jumpers

XPOW (2-pole)

XRO1 (3-pole)

XRO2 (3-pole)

XD24 (4-pole)

DI/DIO ground selection

XDI (6-pole)

XDIO (2-pole)

XAI (7-pole)

AI1, AI2

XAO (4-pole)

XD2D (3-pole)

XSTO (4-pole)


Jumpers

DI/DIO grounding selector (located between XD24 and XDI) – Determines whether the DIGND (ground for digital inputs DI1…DI4) floats, or if it is connected to DIOGND

(ground for DI5, DIO1 and DIO2). (See the JCU isolation and grounding diagram on page

87

.)

If DIGND floats, the common of digital inputs DI1…DI4 should be connected to

XD24:2. The common can be either GND or V cc type.

as DI1…DI4 are of the NPN/PNP

DIGND floats

2

3

4

DIGND tied to DIOGND

2

3

4

1

2

1

2

AI1 – Determines whether Analog input AI1 is used as a current or voltage input.

Current

7

AI1

AI2

1

Voltage

7

AI1

AI2

1

AI2 – Determines whether Analog input AI2 is used as a current or voltage input.

Current

7

AI1

AI2

1

Voltage

7

AI1

AI2

1

T – Drive-to-drive link termination. Must be set to the ON position when the drive is the last unit on the link.

Termination ON

T

Termination OFF

T


External power supply for the JCU Control Unit (XPOW)

External +24 V (minimum 1.6 A) power supply for the JCU 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 supply

• fieldbus communication is required when the input power supply is disconnected.

DI5 (XDI:5) as a thermistor input

1…3 PTC sensors can be connected to this input for motor temperature measurement.

One sensor Three sensors

Motor

T

3.3 nF

> 630 V AC

XDI:5

XD24:1

Motor

T T T

3.3 nF

> 630 V AC

XDI:5

XD24:1

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.

• The connection of temperature sensors involves parameter adjustment. See the

Firmware manual of the drive.

Pt100 sensors are not to be connected to the thermistor input. Instead, an analog input and an analog current output (located either on the JCU or on an I/O extension module) are used as shown below. The analog input must be set to voltage.

One Pt100 sensor

Motor

T

3.3 nF

> 630 V AC

AI1+ (U)

AI1- (U)

AOx (I)

AGND

Three Pt100 sensors

Motor

T T T

3.3 nF

> 630 V AC

AI1+ (U)

AI1- (U)

AOx (I)

AGND


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 terminals must be protected against contact and must not be connected to other equipment or

• the temperature sensor must be isolated from the I/O terminals.

Start interlock (XDI:A)

Terminal XDI:A must be jumpered to XD24:3 to enable the drive start.

Drive-to-drive link (XD2D)

The drive-to-drive link is a daisy-chained RS-485 transmission line that allows basic master/follower communication with one master drive and multiple followers.

Termination activation jumper T (see section

Jumpers

above) next to this terminal

block must be set to the ON position on the drives at the ends of the drive-to-drive link. On intermediate drives, the jumper must be set to the OFF position.

Shielded twisted-pair cable (~100 ohm, e.g. PROFIBUS-compatible cable) must be used for the wiring. For best immunity, high quality cable is recommended. The cable should be kept as short as possible; the maximum length of the link is 50 metres

(164 ft). Unnecessary loops and running the cable near power cables (such as motor cables) must be avoided. The cable shields are to be grounded to the control cable

clamp plate on the drive as shown on page

67

.

The following diagram shows the wiring of the drive-to-drive link.

XD2D

Termination ON

JCU

Drive 1

XD2D

Termination OFF

JCU

Drive 2

...

XD2D

Termination ON

JCU

Drive n


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

40

.

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 left (two of the screws are also used to hold the cover mounting bracket). The plate can be fitted either at the top or bottom of the drive.

Before connecting the wires, run the cables through the cover mounting bracket as shown in the drawing below.

The shields should be continuous as close to the terminals of the JCU as possible.

Only remove the outer jacket of the cable at the cable clamp so that the clamp presses on the bare shield. At the terminal block, use shrink tubing or insulating tape to contain any stray strands. The shield (especially in case of multiple shields) can also be terminated with a lug and fastened with a screw at the clamp plate. Leave the other end of the shield unconnected or ground it indirectly via a few nanofarads highfrequency capacitor (e.g. 3.3 nF / 630 V). 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.

Keep any signal wire pairs twisted as close to the terminals as possible. Twisting the wire with its return wire reduces disturbances caused by inductive coupling.

Re-install the cover assembly according to the instructions on page

49

.


Mounting the clamp plate Routing the control cables

0.7 N·m

(6.2 lbf·in)

Run cables through the cover mounting bracket

Use shrink tubing or tape to contain strands.

Remove outer jacket of cable at clamp to expose cable shield.

Tighten clamp to 1.5 N·m

(13 lbf·in).

Installation checklist 69

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


on the first pages of this manual before you work on the unit.

Check

MECHANICAL INSTALLATION

The ambient operating conditions are allowable. (See

Mechanical installation, Technical data

:

Ratings

,


.)

The unit is fastened properly to the cabinet. (See


and

Mechanical installation.

)

The cooling air will flow freely.

The motor and the driven equipment are ready for start. (See

Planning the electrical

installation, Technical data

: Motor connection

.)

ELECTRICAL INSTALLATION (See

Planning the electrical installation, Electrical installation.

)

The VAR (frames A and B) and EMC/VAR1/VAR2 (frames C and D) screws are removed if the drive is connected to an IT (ungrounded) supply network.

The capacitors are reformed if stored over one year (ask local ABB representative for more information).

The drive is grounded properly.

The supply (input power) voltage matches the drive nominal input voltage.

70 Installation checklist

Check

The supply (input power) is connected to U1/V1/W1 (UDC+/UDC- in case of a DC supply) and the terminals are tightened to specified torque.

Appropriate supply (input power) fuses and disconnector are installed.

The motor is connected to U2/V2/W2, and the terminals are tightened to specified torque.

The motor cable is routed away from other cables.

There are no power factor compensation capacitors in the motor cable.

The external control connections to the JCU Control Unit are OK.

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.

Maintenance 71

Maintenance


This chapter contains preventive maintenance instructions.

Safety

WARNING! Read the


on the first pages of this manual before performing any maintenance on the equipment. Ignoring the safety instructions can cause injury or death.

72 Maintenance

Maintenance intervals

The table below lists the routine maintenance intervals recommended by ABB.

Consult a local ABB Service representative for more details. On the Internet, go to http://www.abb.com/drives , select Drive Services, and Maintenance and Field

Services.

Interval

Every year of storage

Every 6 to 12 months depending on the dustiness of the environment

Every year

Maintenance Instruction

DC capacitor reforming See

Reforming the capacitors

on page

75

.

Heatsink temperature check and cleaning

Inspection of tightness of power connections

Visual inspection of cooling fan

Cooling fan replacement

See

Heatsink

on page

72

.

See pages

56

-

58

.

See

73

.

Cooling fan

on page

See

Cooling fan

on page

73

.

Every 3 years if the ambient temperature is higher than 40 °C (104 °F).

Otherwise, every 6 years.

Every 6 years if the ambient temperature is higher than 40 °C (104 °F) or if the drive is subjected to cyclic heavy load or continuous nominal load.

Otherwise, every 9 years.

Every 10 years

JPU unit replacement

(only frame sizes A and B)

JCAP board replacement (only

frame sizes C and D)

Control panel battery replacement

Contact your local ABB

Service representative.

Contact your local ABB

Service representative.

The battery is housed on the rear of the control panel. Replace with a new CR 2032 battery.

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 necessary):

1. Remove the cooling fan (see section

Cooling fan

).

2. Blow clean compressed air (not humid) from bottom to top and simultaneously use a vacuum cleaner at the air outlet to trap the dust. Note: If there is a risk of the dust entering adjoining equipment, perform the cleaning in another room.

3. Refit the cooling fan.

Maintenance 73

Cooling fan

The actual lifespan of the cooling fan depends on the drive usage and ambient temperature. Fan failure can be predicted by the increasing noise from fan bearings and the gradual rise in the heatsink temperature in spite of heatsink cleaning. If the drive is operated in a critical part of a process, fan replacement is recommended once these symptoms start appearing. Replacement fans are available from ABB. Do not use other than ABB-specified spare parts.

Fan replacement (Frames A and B)

Detach the power cable clamp plate and terminal blocks. Release the retaining clips

(arrowed) carefully using a screwdriver. Pull the fan holder out. Disconnect the fan cable. Carefully bend the clips on the fan holder to free the fan.

Install new fan in reverse order.

Note: The airflow direction is bottom-to-top. Install the fan so that the airflow arrow points up.

Airflow direction

74 Maintenance

Fan replacement (Frames C and D)

To remove the fan, release the retaining clip (arrowed) carefully using a screwdriver.

Pull the fan holder out. Disconnect the fan cable. Carefully bend the clips on the fan holder to free the fan.

Install new fan in reverse order.

Note: The airflow direction is bottom-to-top. Install the fan so that the airflow arrow points up.

Airflow direction

Maintenance 75

Reforming the capacitors

The capacitors must be reformed if the drive has been stored for a year or more. See page

35

for information on finding out the manufacturing date. For information on reforming the capacitors, contact your local ABB representative.

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 the drive module is powered.

After power-up, the drive will scan the memory unit. If a different application program or different parameter settings are detected, they are copied to the drive. This takes about 10 to 30 seconds; the drive will not respond while copying is in progress.

76 Maintenance

Technical data 77

Technical data


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

The nominal ratings with 400 V AC supply are given below.

-02A7-4

-03A0-4

-03A5-4

-04A9-4

-06A3-4

-08A3-4

-11A0-4

-14A4-4

-021A-4

-028A-4

-035A-4

-040A-4

-053A-4

-067A-4

-080A-4

Drive type

ACQ810-04…

C

C

C

B

B

A

B

A

A

A

A

D

D

C

D

Frame size

Input ratings

I

1N

A

2,1

2,6

2,9

4,5

5,2

6,9

9,2

12,6

17

24

29

34

48

56

70

*I

1N

A

-

-

-

9

10

14

18

5

8

3

5

-

-

-

-

I

2N

A

2,7

3

3,5

4,9

6,3

8,3

11

14,4

21

28

35

40

53

67

80

Nominal

I

max

Output ratings

IEC M2/M3

I

cont

I P

A A A kW

4,4

5,3

7

8,8

3

3,6

4,8

6

2,65 1,1

-

3,5 1,5

4,85 2,2

10,5 8 6,3

13,5 10,5 8,29

16,5

21

14

18

10,9

14,4

3

4

5,5

7,5

33

36

53

25

30

44

20,87

27,97

34,12

11

15

18,5

66

78

100

124

50 39,44 22

61 53 30

78

94

67

80

37

45

UL NEMA

I P

A

-

7,6

11

14

21

27

34

2,1

3

3,4

4,8

40

52

65

77 hp

-

5

7,5

10

15

20

25

1

1,5

2

3

30

40

50

60

00581898

78 Technical data

I

I

I

1N

2N max

Nominal input current (rms)

*Without mains choke.

Nominal output current. 110% overload 1 min / 5 min.

Maximum output current. Available for 10 seconds at start, otherwise as long as allowed by drive temperature.

I

cont

P

Continuous rms output current with no overload capacity

Typical motor power

Note 1: The ratings apply at an ambient temperature of 40 °C (+104 °F). In lower temperatures the ratings are higher (except I max

).

Note 2: 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.

The DriveSize dimensioning tool available from ABB is recommended for selecting the drive, motor and gear combination.

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 applicable derating factors.

Ambient temperature derating

In the temperature range +40…55 °C (+104…131 °F), the rated output current is derated by 1% for every added 1 °C (1.8 °F) as follows:

Derating factor

1.00

0.85

+40 °C

+104 °F

+55 °C

+131 °F

Ambient temperature

Technical data 79

The continuous rms output currents with no overload capacity at different ambient temperatures (45 °C, 50 °C and 55 °C) are given below.

Drive type

ACQ810-04-…

-02A7-4

-03A0-4

-03A5-4

-04A9-4

-06A3-4

-08A3-4

-11A0-4

-14A4-4

-021A-4

-028A-4

-035A-4

-040A-4

-053A-4

-067A-4

-080A-4

Frame size

B

B

C

A

B

A

A

A

A

C

D

C

C

D

D

I

cont45

A

2,9

3,4

4,6

5,7

7,6

10

13,3

17,1

24

29

42

48

58

74

89

I

cont50

A

2,7

3,2

4,3

5,4

7,2

9,5

12,6

16,2

23

27

40

45

55

70

85

I

cont55

A

2,6

3,1

4,1

5,1

6,8

8,9

11,9

15,3

21

26

37

43

52

66

80

00581898

I

contxx

Continuous rms output current at specified temperature maximum, no overloading

Altitude derating

At altitudes from 1000 to 4000 m (3300 to 13123 ft) above sea level, the derating is

1% for every 100 m (328 ft). For a more accurate derating, use the DriveSize PC tool.

Note: If the installation site is higher than 2000 m (6600 ft) above sea level, connection of the drive to an ungrounded (IT) or corner-grounded delta network is not allowed.

80 Technical data

Dimensions

See also chapter


on page

109

.

Frame size

A

B

C

D

Height

(without cable clamp plates)

Height (with cable clamp plates)

Height (with

C3 filter, no cable clamps)

Height (with

C3 filter and cable clamps)

Width

mm (in.) mm (in.) mm (in.) mm (in.) mm (in.)

364 (14.33) 474 (18.66) 518 (20.37) 628 (24.72) 94 (3.68)

380 (14.96) 476 (18.74) 542 (21.34) 644 (25.35) 101 (3.97)

567 (22.31) 658 (25.9) 567 (22.31) 658 (25.9) 166 (6.52)

567 (22.31) 744 (29.28) 567 (22.31) 744 (29.28) 221 (8.69)

Depth

(without control panel) mm (in.)

197 (8)

275 (11)

276 (11)

276 (11)

Depth

(with control panel) mm (in.)

219 (8.62)

297 (11.68)

298 (11.74)

298 (11.74)

Cooling characteristics, noise levels, weights

Drive type

ACQ810-04…

-02A7-4

-03A0-4

-03A5-4

-04A9-4

-06A3-4

-08A3-4

-11A0-4

-14A4-4

-021A-4

-028A-4

-035A-4

-040A-4

-053A-4

-067A-4

-080A-4

Power loss

W

100

106

126

148

172

212

250

318

375

375

541

646

840

1020

1200

Air flow

m

3

/h (ft

3

/min)

24 (14)

24 (14)

24 (14)

24 (14)

24 (14)

48 (28)

48 (28)

48 (28)

142 (84)

142 (84)

200 (118)

200 (118)

290 (171)

290 (171)

290 (171)

Noise level

dBA

47

47

47

39

39

63

47

47

39

63

71

71

70

70

70

Weight

kg (lb)

3.2 (7.1)

3.2 (7.1)

3.2 (7.1)

3.2 (7.1)

3.2 (7.1)

5.4 (11.9)

5.4 (11.9)

5.4 (11.9)

15.6 (34.4)

15.6 (34.4)

15.6 (34.4)

15.6 (34.4)

21.3 (46.9)

21.3 (46.9)

21.3 (46.9)

Technical data 81

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. Check that the operating time of the fuse is below 0.5 seconds. The operating time depends on the supply network impedance and the cross-sectional area and length of the supply cable. See also chapter


.

Note: Fuses with a higher current rating must not be used.

Drive type

ACQ810-04…

-02A7-4

-03A0-4

-03A5-4

-04A9-4

-06A3-4

-08A3-4

-11A0-4

-14A4-4

-021A-4

-028A-4

-035A-4

-040A-4

-053A-4

-067A-4

-080A-4

*Without mains choke

18*

17

24

29

34

48

56

3*

5*

5*

8*

9*

10*

14*

70

Input current

(A)

IEC fuse

50

63

80

25

25

32

50

100

Rated current

(A)

16

16

20

6

6

10

10

Voltage

(V)

Class

500

500

500

500

500

500

500

500

500

500

500

500

500

500

500 gG gG gG gG gG gG gG gG gG gG gG gG gG gG gG

UL fuse

50

70

80

25

25

35

45

100

Rated current

(A)

15

15

20

6

6

10

10

Voltage

(V)

600

600

600

600

600

600

600

600

600

600

600

600

600

600

600

UL

Class

T

T

T

T

T

T

T

T

T

T

T

T

T

T

T

Cross-sectional area of cable

mm

2

AWG

1.5 … 4 16…12

1.5 … 4 16…12

1.5 … 4 16…12

1.5 … 4 16…12

1.5 … 4 16…12

1.5 … 10 16…8

1.5 … 10 16…8

1.5 … 10 16…8

6…35 9…2

6…35

6…35

9…2

9…2

10…70 6 … 2/0

10…70 6 … 2/0

10…70 6 … 2/0

10…70 6 … 2/0

82 Technical data

Low harmonic filters

A passive low harmonic filter is designed to decrease the Total Harmonic Distortion of incoming current (THDI) below 5%. Filter type Schaffner ECOsine™ is used with

ACQ810. Filters are dimensioned to achieve THDI requirement at nominal load. THD increases at partial load and can be higher than 5% at no-load.

400 V / 50 Hz

Drive type

ACQ810-04-…

-02A7-4

-03A5-4

-04A9-4

-08A3-4

-11A0-4

-14A4-4

-021A-4

-028A-4

-035A-4

-040A-4

-053A-4

-067A-4

-080A-4

B

B

C

C

A

B

A

A

C

C

D

D

D

Frame size

Nominal ratings

P

(kW)

1,1

1,5

2,2

4

5,5

7,5

11

15

18,5

22

30

37

45

400 V/ 50 Hz

Filter type

*

FN 3410-10-44

FN 3410-13-44

FN 3410-16-44

FN 3410-24-33

FN 3410-32-33

FN 3410-38-33

FN 3410-45-34

FN 3410-60-34

FN 3410-75-35

FN 3410-90-35

Height

mm

-

400

400

430

520

520

520

590

590

750

750

Width

mm

-

170

170

210

250

250

250

300

300

320

320

Depth

mm

Weight

kg

-

190

190

210

280

280

280

300

300

300

300

-

31

35

45

54

13

14

21

27

65

77

00581898

Technical data 83

460 V / 60 Hz

Drive type

ACQ810-04-…

-02A7-4

-03A0-4

-03A5-4

-04A9-4

-08A3-4

-11A0-4

-14A4-4

-021A-4

-028A-4

-035A-4

-040A-4

-053A-4

Frame size

B

B

B

C

A

A

A

A

C

C

C

D

20

25

30

40

5

7,5

10

15

Nominal ratings

P

(hp)

1

1,5

2

3

460 V / 60 Hz

Filter type

*

FN 3412-8-44

FN 3412-11-44

FN 3412-15-44

FN 3412-21-44

FN 3412-28-33

FN 3412-35-33

FN 3412-41-33

FN 3412-53-34

Height

mm

-

400

400

430

430

520

520

520

590

Width

mm

-

170

170

210

210

250

250

250

300

Depth

mm

-

190

190

210

210

280

280

280

300

Weight

kg

-

28

32

45

48

12

13

17

21

-067A-4

-080A-4

D

D

50

60

FN 3412-65-34

FN 3412-80-35

590

750

300

320

300

300

52

69

00581898

* Smallest filter is for power 4 kW. This filter can be used at lower power, but the THD of the line current will increase. E.g. at power 1,1 kW THDI is approximately 12% when using filter type FN3410-10-44.

Note: If the supply voltage is 480 V, one step smaller filter must be used at the same power. E.g. at supply voltage 400 V and power 11 kW the filter selection is FN 3410-

24-33, but at 480 V and 11 kW the selection is FN 3410-16-44.

For further information, see www.schaffner.com

or contact your local ABB office.

84 Technical data

AC input (supply) connection

Voltage (U

Frequency

1

)

380 … 480 V AC +10%/-15%, 3-phase

50 … 60 Hz ±5%

Network type

Imbalance

Fundamental power factor (cos phi

1

)

Terminals

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 higher.

Max. ±3% of nominal phase to phase input voltage

0.98 (at nominal load)

Frame A: Detachable screw terminal block for 0.25 … 4 mm

2

wire.

Frame B: Detachable screw terminal block for 0.5 … 6 mm

Frames C and D: Screw lugs for 6…70 mm

2

2

wire.

wire included. Suitable crimp lugs can be used instead.

DC connection

Voltage

Ratings, fuse recommendations

436 … 743 V DC

Terminals

Drive type

ACQ810-04…

-02A7-4

-03A0-4

-03A5-4

-04A9-4

-06A3-4

-08A3-4

-11A0-4

-14A4-4

-021A-4

-028A-4

-035A-4

-040A-4

-053A-4

-067A-4

-080A-4

I

dcN

(A)

38

54

54

12

15

20

29

3.3

3.9

4.8

6.5

8.7

73

85

98

C

(µF)

370

740

740

670

670

1000

1000

120

120

240

240

240

1340

2000

2000

20

32

32

63

63

63

100

Rated current

(A)

16

16

16

16

16

DC fuse

Voltage

(V)

690

690

690

690

690

160

160

160

690

690

690

690

690

690

690

690

690

690

Class aR aR aR aR aR aR aR aR aR aR aR aR aR aR aR

I

dcN

Average DC input current requirement when running a typical induction motor at P

N

at a

DC link voltage of 540 V (which corresponds to an AC input voltage of 400 V).

Capacitance of DC link.

C


2

wire.



2

2

wire.


Motor connection

Motor types

Voltage (U

2

)

Asynchronous induction motors

0 to U

1

, 3-phase symmetrical, U max

at the field weakening point

Technical data 85

Frequency

Current

Switching frequency

Maximum motor cable length

Terminals

0 … 500 Hz

See section

Ratings.

3 kHz as default.

Frames A and B: 150 m (492 ft) *

Frames C and D: 300 m (984 ft) *

*100 m with EN 61800-3 Category C3 filter

Note: With motor cables longer than 100 m (328 ft) the EMC Directive requirements may not be fulfilled.


2

wire.


2


2

wire.


JCU Control Unit

Power supply

Relay outputs RO1…RO2

(XRO1 … XRO2)

24 V (±10%) DC, 1.6 A

Supplied from the power unit of the drive, or from an external power supply through connector XPOW (pitch 5 mm, wire size 2.5 mm

2

).

Connector pitch 5 mm, wire size 2.5 mm

2

250 V AC / 30 V DC, 2 A

Protected by varistors

Note: At installation sites between 2000 meters (6562 feet) and 4000 meters

(13123 feet), the Protective Extra Low Voltage (PELV) requirements are not fulfilled if a relay output is used with a voltage greater than 48 V.

Connector pitch 5 mm, wire size 2.5 mm

2

+24 V output

(XD24)

Digital inputs DI1…DI5

(XDI:1 … XDI:5)

Start interlock input DIIL

(XDI:A)

Digital inputs/outputs

DIO1 and DIO2

(XDIO:1 and XDIO:2)

Input/output mode selection by parameters.

DIO1 can be configured as a frequency input (0…16 kHz) for 24 V level square wave signal (sinusoidal or other wave form cannot be used). DIO2 can be configured as a 24 V level square wave frequency output. See the Firmware

manual, parameter group

12.

Connector pitch 3.5 mm, wire size 1.5 mm

2

24 V logic levels: “0” < 5 V, “1” > 15 V

R

in

: 2.0 kohm

Input type: NPN/PNP (DI1…DI4), NPN (DI5)

Filtering: 0.25 ms

DI5 (XDI:5) can alternatively be used as an input for 1…3 PTC thermistors.

“0” > 4 kohm, “1” < 1.5 kohm

I

max

: 15 mA

Wire size 1.5 mm

2

24 V logic levels: “0” < 5 V, “1” > 15 V

R

in

: 2.0 kohm

Input type: NPN/PNP

Filtering: 0.25 ms


2

As inputs:

24 V logic levels: “0” < 5 V, “1” > 15 V

R

in

: 2.0 kohm

Filtering: 0.25 ms

As outputs:

Total output current limited by auxiliary voltage outputs to 200 mA

Output type: Open emitter

V

CC

DIOx

R

L

DGND

86 Technical data

Reference voltage for analog inputs +VREF and -VREF

(XAI:1 and XAI:2)

Analog inputs AI1 and

AI2 (XAI:4 … XAI:7).

Current/voltage input mode selection by jumpers. See page

Drive to drive link

(XD2D)

Safe torque off

Control panel / PC connection

64

connection (XSTO)

.

Analog outputs AO1 and

AO2

(XAO)


10 V ±1% and –10 V ±1%, R load

> 1 kohm

2


2

Current input: –20…20 mA, R in:

Voltage input: –10…10 V, R in

100 ohm

: 200 kohm

Differential inputs, common mode ±20 V

Sampling interval per channel: 0.25 ms

Filtering: 0.25 ms

Resolution: 11 bit + sign bit

Inaccuracy: 1% of full scale range


2

0…20 mA, R load

< 500 ohm

Frequency range: 0…800 Hz

Resolution: 11 bit + sign bit

Inaccuracy: 2% of full scale range


2

Physical layer: RS-485

Termination by jumper


2

For the drive to start, both connections (OUT1 to IN1, and OUT2 to IN2) must be closed

Connector: RJ-45

Cable length < 3 m

Technical data 87

Isolation and grounding diagram

XDIO

1

2

6

7

4

5

XAI

1

2

3

3

4

XAO

1

2

DIO1

DIO2

+VREF

-VREF

AGND

AI1+

AI1-

AI2+

AI2-

AO1+

AO1-

AO2+

AO2-

XD2D

1

2

3

B

A

BGND

2

3

4

XSTO

1 OUT1

OUT2

IN1

IN2

XPOW

1

2

+24VI

GND

XDI

1

4

5

2

3

A

4

5

6

1

2

XRO1…XRO2

3

NO

COM

NC

NO

COM

NC

2

3

4

XD24

1 +24VD

DIGND

+24VD

DIOGND

DI1

DI2

DI3

DI4

DI5

DIIL

Ground

Common mode voltage between channels ± 20 V

Efficiency

Approximately 98% at nominal power level

Cooling

Method

Free space around the unit

Internal fan, flow from bottom to top. Air-cooled heatsink.

See chapter


.

Degrees of protection

IP20 (UL open type). See chapter

Planning the cabinet assembly .

88 Technical data

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 to 4000 m (13123 ft) above sea level. [See section

Derating

on page

78

.]

Air temperature

-10 to +55°C (14 to

131°F).

No frost allowed.

See section

Derating

on page

78

.

-40 to +70°C (-40 to

+158°F)

-40 to +70°C (-40 to

+158°F)

Relative humidity

0 to 95% Max. 95% Max. 95%

Contamination levels

(IEC 60721-3-3,

IEC 60721-3-2,

IEC 60721-3-1)

Sinusoidal vibration

(IEC 60721-3-3)

Shock

(IEC 60068-2-27, ISTA

1A)

Free fall

No condensation allowed. Maximum allowed relative humidity is 60% in the presence of corrosive gases.

No conductive dust allowed.

According to IEC

60721-3-3:

Chemical gases: Class

3C2

Solid particles: Class 3S2

The drive must be installed in clean air according to enclosure classification. Cooling air must be clean, free from corrosive materials and electrically conductive dust.

According to IEC

60721-3-1:

Chemical cases: Class

1C2


According to IEC

60721-3-2:

Chemical cases: Class

2C2


– – Tested according to

IEC 60721-3-3, mechanical conditions:

Class 3M4

2…9 Hz: 3.0 mm (0.12”)

9…200 Hz: 10 m/s ft/s

2

)

2

(33

–

Not allowed

According to ISTA 1A.

Max. 100 m/s

11 ms

2

(330 ft/s

2

),

76 cm (30”)

According to ISTA 1A.

Max. 100 m/s

11 ms

2

(330 ft/s

2

),

76 cm (30”)

Materials

Drive enclosure

Packaging

• PC/ABS, colour NCS 1502-Y (RAL 9002 / PMS 420 C)

• hot-dip zinc coated steel sheet

• extruded aluminium AlSi.

Corrugated cardboard, PP bands.

Technical data 89

Disposal

The drive contains raw materials that should be recycled to preserve energy and natural resources. The package materials are environmentally compatible and recyclable. All metal parts can be recycled. The plastic parts can either be recycled or burned under controlled circumstances, according to local regulations. Most recyclable parts are marked with recycling marks.

If recycling is not feasible, all parts excluding electrolytic capacitors and printed circuit boards can be landfilled. The DC capacitors contain electrolyte, which is classified as hazardous waste within the EU. They must be removed and handled according to local regulations.

For further information on environmental aspects and more detailed recycling instructions, please contact your local ABB distributor.

Applicable standards

•

•

EN 50178:1997

IEC 60204-1:2006

•

EN 61800-3:2004

•

EN 61800-5-1:2003

The drive complies with the following standards. The compliance with the

European Low Voltage Directive is verified according to standards EN 50178 and EN 60204-1.

Electronic equipment for use in power installations

Safety of machinery. Electrical equipment of machines. Part 1: General requirements. Provisions for compliance: The final assembler of the machine is responsible for installing

- an emergency-stop device

- a supply disconnecting device

- the drive module into a cabinet.

Degrees of protection provided by enclosures (IP code)

•

EN 60529:1991

(IEC 60529)

•

IEC 60664-1:2007

•

IEC/EN 61000-3-12:

2004

•

EN 61800-5-2:2007

•

UL 508C:2002, Third

Edition

•

NEMA 250:2003

•

CSA C22.2 No. 14-05

(2005)

Insulation coordination for equipment within low-voltage systems. Part 1:

Principles, requirements and tests.

Electromagnetic compatibility (EMC). Part 3-12: Limits. Limits for harmonic currents produced by equipment connected to public low-voltage systems with input current >16 A and <75 A per phase. Provisions for compliance:

- With converters ACQ810-04-14A4-4…021A-4 IEC61000-3-12 is fulfilled with short-circuit-ratio >120 and supply short-circuit current <3.6 kA

- With converters ACQ810-04-028A-4…080A-4 IEC61000-3-12 is fulfilled with short-circuit-ratio >120 and supply short-circuit current <14 kA.

Short-circuit-ratio is defined as a ratio of supply short-circuit current and converter’s incoming current.

Adjustable speed electrical power drive systems. Part 3: EMC requirements and specific test methods.

Adjustable speed electrical power drive systems.

Part 5-1: Safety requirements. Electrical, thermal and energy

Provisions for compliance: The final assembler of the machine is responsible for installing the ACQ810-04 in a cabinet that is protected to IP3X for top surfaces for vertical access.

Adjustable speed electrical power drive systems.

Part 5-2: Safety requirements – Functional

UL Standard for Safety, Power Conversion Equipment

Enclosures for Electrical Equipment (1000 Volts Maximum)

Industrial Control Equipment

90 Technical data

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.

Compliance with the European Low Voltage Directive

The compliance with the European Low Voltage Directive has been verified according to standards EN 50178, EN 61800-5-1 and EN 60204-1.

Compliance with the European EMC Directive

The cabinet builder is in responsible for the compliance of the drive system with the

European EMC Directive. For information on items to consider, see:

• Subsections

Compliance with EN 61800-3:2004, category C2

;

Compliance with

EN 61800-3:2004, category C3

; and

Compliance with EN 61800-3:2004, category

C4

below

• The chapter


in this manual

• Technical Guide No. 3 – EMC Compliant Installation and Configuration for a

Power Drive System [3AFE61348280 (English)].

Definitions

EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to operate without problems within an electromagnetic environment.

Likewise, the equipment must not disturb or interfere with any other product or system within its locality.

First environment includes domestic premises. It also includes establishments

directly connected without intermediate transformers to a low-voltage network which supplies buildings used for domestic purposes.

Second environment includes all establishments other than those directly connected

to a low-voltage network which supplies buildings used for domestic purposes.

Drive of category C2. Power drive system with rated voltage less than 1000 V which

is neither a plug-in device nor a movable device and, when used in the first environment, is intended to be installed and commissioned only by a professional.

Drive of category C3. Power drive system with rated voltage less than 1000 V,

intended for use in the second environment and not intended for use in the first environment.

Drive of category C4. Power drive system with rated voltage equal to or above

1000 V, or rated current equal to or above 400 A, or intended for use in complex systems in the second environment.

Technical data 91

Compliance with EN 61800-3:2004, category C2

The drive meets the requirements of the EMC Directive with the following provisions:

1. The drive is equipped with external EMC filter JFI-0x.

2. The motor and control cables are selected as specified in the chapter


.

3. The drive is installed according to the instructions given in this manual.

4. Motor cable length does not exceed 100 metres (328 ft).

Note: It is not allowed to use the optional EMC filter on IT (ungrounded) systems. The supply network becomes connected to ground potential through the EMC filter capacitors which may cause danger or damage the drive.

Note: It is not allowed to use the optional EMC filter on a corner-grounded TN system as this would damage the drive.

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.





.


3. Motor cable length does not exceed 100 metres (328 ft).



1. The drive is equipped with filtering option +0E200.

2. It is ensured that no excessive emission is propagated to neighbouring lowvoltage networks. In some cases, the natural suppression in transformers and cables is sufficient. If in doubt, a supply transformer with static screening between the primary and secondary windings can be used.

92 Technical data

Medium voltage network

Point of measurement

Low voltage

Neighbouring network

Equipment

Equipment

Supply transformer

Static screen

Low voltage

Equipment

Drive

3. An EMC plan for preventing disturbances is drawn up for the installation. A template is available from the local ABB representative.



.


Compliance with the Machinery Directive

The drive is intended to be incorporated into machinery to constitute machinery covered by Machinery Directive and does therefore not in every respect comply with the provisions of the directive.

C-Tick marking

Pending.

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

38

.

Ambient conditions – The drive is to be used in a heated indoor controlled

environment. See section


on page

88

for specific limits.

Input cable fuses – For installation in the United States, branch circuit protection must be provided in accordance with the National Electrical Code (NEC) and any applicable local codes. To fulfill this requirement, use the UL classified fuses given in

section

Supply cable fuses

on page

81

.

Technical data 93

For installation in Canada, branch circuit protection must be provided in accordance with the Canadian Electrical Code and any applicable provincial codes. To fulfil this

requirement, use the UL classified fuses given in section

Supply cable fuses

on page

81

.

Power cable selection – See section


on page

41

.

Power cable connections – For the connection diagram and tightening torques, see

section


on page

52

.

Control connections – For the connection diagram and tightening torques, see

section

Connecting the control cables

on page

62

.

Overload protection – The drive provides overload protection in accordance with the National Electrical Code (US).

UL standards – See section

Applicable standards

on page

89

.

Patent protection in the US

This product is protected by one or more of the following US patents:

4,920,306

5,532,568

5,799,805

6,094,364

6,195,274

6,305,464

6,370,049

6,552,510

6,774,758

6,922,883

6,958,923

6,984,958

7,023,160

7,057,908

7,084,604

7,164,562

7,221,152

7,262,577

7,280,938

7,365,622

7,417,408

7,515,447

D510,320

D512,696

D541,745S

Other patents pending.

5,301,085

5,589,754

5,940,286

6,147,887

6,229,356

6,313,599

6,396,236

6,597,148

6,844,794

6,940,253

6,967,453

6,985,371

7,034,510

7,059,390

7,098,623

7,176,779

7,227,325

7,271,505

7,330,095

7,372,696

7,446,268

7,560,894

D511,137

D521,466

D548,182S

5,463,302

5,612,604

5,942,874

6,175,256

6,252,436

6,316,896

6,448,735

6,600,290

6,856,502

6,934,169

6,972,976

5,521,483

5,654,624

5,952,613

6,184,740

6,265,724

6,335,607

6,498,452

6,741,059

6,859,374

6,956,352

6,977,449

6,992,908

7,036,223

7,067,997

7,102,325

7,190,599

7,245,197

7,274,573

6,999,329

7,045,987

7,082,374

7,109,780

7,215,099

7,250,739

7,279,802

7,349,814 7,352,220

7,388,765 7,408,791

7,456,615

D503,931

7,508,688

D510,319

D511,150

D541,743S

D512,026

D541,744S

D548,183S D573,090S

94 Technical data

Mains chokes 95

Mains chokes


This chapter describes how to select and install mains chokes for the ACQ810-04.

The chapter also contains the relevant technical data.

When is a mains choke required?

Frame C and D drive modules have an internal mains choke. With frames A and B, the need for an external choke should be determined on a case-by-case basis. The main choke typically

• reduces harmonics in the input current

• reduces the r.m.s. input current

• reduces supply disturbance and low-frequency interference

• increases the allowed DC bus continuous power

• ensures even current distribution in common DC configurations (see page

59

).

96 Mains chokes

Selection table

-02A7-4

Mains chokes for ACQ810-04

Drive type

ACQ810-04…

Type

CHK-01 -03A0-4

-03A5-4

-04A9-4

-06A3-4

-08A3-4

CHK-02

CHK-03

-11A0-4

-14A4-4

-021A-4

-028A-4

-035A-4

CHK-04

-040A-4

-053A-4

-067A-4

-080A-4

Inductance

µH

6370

4610

2700

1475

(Internal choke as standard)

00581898

The mains chokes are protected to IP20. Refer to page

116

for dimensions, wire

sizes and tightening torques.

Mains chokes 97

Installation guidelines

• If an EMC filter is also installed, the mains choke is connected between the supply and the EMC filter. See the diagram below.

• For optimal operation of the choke, the drive and the choke must be mounted on the same conductive surface.

• Ensure the choke does not block the airflow through the drive module, and that the air rising from the choke is deflected away from the air inlet of the drive module

• Keep the cable between the drive and the choke as short as possible.

WARNING! The surface of the mains choke becomes hot when in use.

Connection diagram

DC supply

+ –

L1

U

AC supply

V

L2 L3 PE

W PE

CHK-xx mains choke

X Y Z

JFI-xx EMC filter (if present)

UDC+ UDC-

U1 V1 W1

ACQ810-04

~

~

98 Mains chokes

EMC filters 99

EMC filters


This chapter describes how to select and install EMC filters for the ACQ810-04. The chapter also contains the relevant technical data.

When is an EMC filter required?

The EMC product standard (EN 61800-3 + Amendment A11:2000) covers the specific

EMC requirements stated for drives (tested with motor and cable) within the EU. The new revision of 61800-3:2004 product standard can be applied from now on, but from

1st October 2007 at the latest. EMC standards such as EN 55011 or EN 61000-6-3/4 apply to industrial and household equipment and systems including drive components inside. Drive units complying with the requirements of EN 61800-3 are always compliant with comparable categories in EN 55011 and EN 61000-6-3/4, but not necessarily vice versa. EN 55011 and EN 61000-6-3/4 do neither specify cable length nor require a motor to be connected as a load. The emission limits are comparable according to the following table.

EN 61800-3/A11:2000, product standard

1st environment, unrestricted distribution

1st environment, restricted distribution

2nd environment, unrestricted distribution

2nd environment, restricted distribution

EMC standards in general

EN 61800-3:2004, product standard

Category C1

EN 55011, product family standard for industrial, scientific and medical (ISM) equipment

Group 1 Class B

Category C2

Category C3

Category C4

Group 1 Class A

Group 2 Class A

Not applicable

100 EMC filters

Filter type JFI-A1 or JFI-B1 is required in order to meet the category C3 level with the

ACQ810-04 drive installation, including a motor with a max. 100 m cable. This level corresponds to the A limits for Group 2 equipment according to EN 55011. The filter is delivered as standard. With frame sizes A and B, the filter is external; with frame sizes C and D, the filter is internal. If the drive is equipped with filtering option

+0E200, it does not contain the filter.

An external EMC filter of the type JFI-0x is required in order to meet the category C2 level with the ACQ810-04 drive installation, including a motor with a max. 100 m cable. This level corresponds to the A limits for Group 1 equipment according to

EN 55011. The filter is an optional device.

WARNING! An EMC filter must not be installed if the drive is connected to an

IT power system (i.e. an ungrounded, or a high resistance grounded [over 30 ohm] power system).

Selection table

Drive type

ACQ810-04…

-02A7-4

-03A0-4

-03A5-4

-04A9-4

-06A3-4

-08A3-4

-11A0-4

-14A4-4

-021A-4

-028A-4

-035A-4

-040A-4

-053A-4

-067A-4

-080A-4

EMC filters for ACQ810-04

Filter type

EN 61800-3:2004:

Category C3

EN 61800-3:2004:

Category C2

external filter JFI-A1 external filter JFI-B1

internal filter external filter JFI-02 external filter JFI-03 external filter JFI-05 external filter JFI-07

00581898

All EMC filters are protected to IP20. Refer to page

117

for dimensions of the JFI-x1

filters. Refer to page

119

for dimensions, wire sizes and tightening torques of the

JFI-0x filters.

EMC filters 101

JFI-A1/JFI-B1 (Frame A/B, category C3) installation


• The filter is connected directly to the drive input connectors.

• For optimal operation of the filter, the drive and the filter must be mounted on the same conductive surface.


AC supply

L1 L2 L3 PE

DC supply

+ –

CHK-xx mains choke (if present)

U1 V1 W1

UDC+ UDC-

~

~

JFI-x1 EMC filter

ACQ810

102 EMC filters

Mounting procedures

JFI-A1

• Remove the UDC+/- and U1/V1/W1 terminal blocks (1), and the upper power cable clamp plate (2) from the drive.

• Fasten the mounting bracket (3) to the drive module base with two screws (4).

Tighten to 1.5 N·m (13 lbf·in).

• Push the filter into place through the mounting bracket.

• Fasten the filter to the mounting bracket with two screws (5). Tighten to 1.5 N·m

(13 lbf·in).

• Fasten the top edge of the filter to the mounting base with two screws (6).

• Fasten the power cable clamp plate at the top of the filter. Tighten to 1.5 N·m

(13 lbf·in).

• Attach the terminal blocks to the filter.

2

1

6

5

4

3

EMC filters 103

JFI-B1

• Remove the UDC+/- and U1/V1/W1 terminal blocks (1), and the upper power cable clamp plate (2) from the drive.

• Push the filter into the connectors.

• Fasten the filter to the drive module base with two screws (3). Tighten to 1.5 N·m

(13 lbf·in).

• Fasten the top edge of the filter to the mounting base with two screws (4).

• Fasten the power cable clamp plate at the top of the filter. Tighten to 1.5 N·m

(13 lbf·in).

• Attach the terminal blocks to the filter.

2

1

4

3

104 EMC filters

JFI-0x (Frames A…D, category C2) installation


• If a mains choke is also installed, the EMC filter is connected between the mains choke and the drive module. See the connection diagram below.

• For optimal operation of the filter, the drive and the filter must be mounted on the same conductive surface.

• Ensure the filter does not block the airflow through the drive module.

• Keep the cable between the drive and the filter as short as possible.


AC supply

L1 L2 L3 PE

CHK-xx mains choke (if present)

L1 L2 L3

JFI-0x EMC filter

L1’ L2’ L3’

U1 V1 W1 PE

ACQ810

~

~

du/dt and common mode filtering 105

du/dt and common mode filtering


This chapter describes how to select du/dt and common mode filtering for the

ACQ810-04. The chapter also contains the relevant technical data.

When is du/dt or common mode filtering required?

The output of the drive comprises – regardless of output frequency – pulses of approximately 1.35 times the equivalent supply voltage with a very short rise time.

This is the case with all drives employing modern IGBT inverter technology.

The voltage of the pulses can be almost double at the motor terminals, depending on the attenuation and reflection properties of the motor cable and the terminals. This in turn can cause additional stress on the motor and motor cable insulation.

Modern variable speed drives with their fast-rising voltage pulses and high switching frequencies can generate current pulses that flow through the motor bearings, which can gradually erode the bearing races and rolling elements.

The stress on motor insulation can be avoided by using optional ABB du/dt filters. du/ dt filters also reduce bearing currents. Common mode filtering mainly reduces bearing currents.

To avoid damage to the motor bearings, the cables must be selected and installed

according to the instructions given in chapter


. In addition, du/dt filtering, common mode filtering, and insulated N-end bearings must be used according to the following table.

106 du/dt and common mode filtering

Motor type

Supply voltage (U

N

)

Motor insulation system

Random-wound ABB

M2__, M3__ motors

Form-wound ABB HX_ or modular motor manufactured before

1 Jan 1998

Random-wound ABB

HX_ and AM_ motor manufactured before

1 Jan 1998

Random-wound ABB

HX_ and AM_ motor manufactured from

1 Jan 1998

Other ABB motors, or random-wound or form-wound non-ABB motors

U

U

N

N

< 500 V

< 500 V

Any

Any

U

U

U

N

N

N

< 500 V

< 500 V

< 420 V

420 V < U

N

500 V

<

Enamelled wire with fiberglass taping

Enamelled wire with fiberglass taping

Standard

(Û

LL

= 1300 V)

Standard

(Û

LL

= 1300 V)

Reinforced

(Û

LL

= 1600 V,

0.2 microsecond rise time)

du/dt filtering

–

Check with motor manufacturer

–

–

Yes

–

Requirement

Insulated Nend bearing

–

Yes

Common mode filtering

Check with motor manufacturer

Yes

–

–

–

–

Yes

Yes

–

–

– 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.

du/dt and common mode filtering 107

Filter types

du/dt filters

Drive type

ACQ810-04…

-02A7-4

-03A0-4

-03A5-4

-04A9-4

-06A3-4

-08A3-4

-11A0-4

-14A4-4

-021A-4

-028A-4

-035A-4

-040A-4

-053A-4

-067A-4

-080A-4

NOCH0016-60*

NOCH0030-60*

NOCH0070-60*

NOCH0120-60**

* 3-phase

** 1-phase; three filters included in kit

du/dt filters for ACQ810-04

IP00

Filter type

IP22

NOCH0016-62*

NOCH0030-62*

NOCH0070-62*

NOCH0120-62**

Common mode filters

Contact your local ABB representative.

IP54

NOCH0016-65*

NOCH0030-65*

NOCH0070-65*

NOCH0120-65**

108 du/dt and common mode filtering

Technical data

du/dt filters

Dimensions and weights

Filter type

NOCH0016-60

NOCH0030-60

NOCH0070-60

NOCH0120-60*

NOCH0016-62

NOCH0030-62

NOCH0070-62

NOCH0120-62*

NOCH0016-65

NOCH0030-65

NOCH0070-65

NOCH0120-65*

* Dimensions given are per phase

Height

mm (inches)

195 (7.68)

215 (8.46)

261 (10.28)

106 (4.17)

323 (12.72)

348 (13.70)

433 (17.05)

765 (30.12)

323 (12.72)

348 (13.70)

433 (17.05)

765 (30.12)

Degree of protection

IP00, IP22 and IP54

Common mode filters

Contact your local ABB representative.

Width

mm (inches)

140 (5.51)

165 (6.50)

180 (7.09)

154 (6.06)

199 (7.83)

249 (9.80)

279 (10.98)

308 (12.13)

199 (7.83)

249 (9.80)

279 (10.98)

308 (12.13)

Installation

Follow the instructions included with the filters.

Depth

mm (inches)

115 (4.53)

130 (5.12)

150 (5.91)

200 (7.87)

154 (6.06)

172 (6.77)

202 (7.95)

256 (10.07)

154 (6.06)

172 (6.77)

202 (7.95)

256 (10.07)

Weight

kg (lbs)

2.4 (5.3)

4.7 (10.4)

9.5 (20.9)

7.0 (15.4)

6 (13.2)

9 (19.8)

15.5 (34.17)

45 (99)

6 (13.2)

9 (19.8)

15.5 (34.17)

45 (99)

Dimension drawings 109

Dimension drawings


Dimension drawings of the ACQ810-04 and related accessories are shown below.

The dimensions are given in millimeters and [inches].

110 Dimension drawings

Frame size A



Frame size B



Frame size C

Frame size D



Mains chokes (type CHK-0x)

68906903

Parameter

dim A mm (in.) dim B mm (in.) dim C mm (in.) dim D mm (in.) dim E mm (in.)

F screw size

Weight kg (lbs)

Wire size – Main terminals

mm

2

(AWG)

CHK-xx dimensions

Choke type

CHK-01 CHK-02 CHK-03 CHK-04

120 (4.72) 150 (5.91) 150 (5.91) 150 (5.91)

146 (5.75) 175 (6.89) 175 (6.89) 175 (6.89)

Tightening torque – Main terminals

N·m (lbf·in)

PE/Chassis terminals

Tightening torque – PE/Chassis terminals

N·m (lbf·in)

79 (3.11) 86 (3.39) 100 (3.94) 100 (3.94)

77 (3.03) 105 (4.13) 105 (4.13) 105 (4.13)

114 (4.49) 148 (5.83) 148 (5.83) 148 (5.83)

M5 M5 M5 M5

1.8 (4.0) 3.8 (8.4) 5.4 (11.9) 5.2 (11.5)

0.5 … 10

(20…6)

0.5 … 10

(20…6)

1.5 (13) 1.5 (13)

0.5 … 10

(20…6)

1.5 (13)

0.5 … 10

(20…6)

1.5 (13)

M4

3 (26)

M5

4 (35)

M5

4 (35)

M5

4 (35)

EMC filters (type JFI-x1)

JFI-A1



JFI-B1

EMC filters (type JFI-0x)



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 and selecting Sales, Support and Service network.

Product training

For information on ABB product training, navigate to www.abb.com/drives and select

Training courses.

Providing feedback on ABB Drives manuals

Your comments on our manuals are welcome. Go to www.abb.com/drives and select

Document Library – Manuals feedback form (LV AC drives).

Document library on the Internet

You can find manuals and other product documents in PDF format on the Internet. Go to www.abb.com/drives and select Document Library. You can browse the library or enter selection criteria, for example a document code, in the search field.

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/drives

ABB Inc.

Automation Technologies

Drives & Motors

16250 West Glendale Drive

New Berlin, WI 53151 USA

Telephone 262 785-3200

800-HELP-365

780-5135

ABB Beijing Drive Systems Co. Ltd.

No. 1, Block D, A-10 Jiuxianqiao Beilu

Chaoyang District

Beijing, P.R. China, 100015

Telephone +86 10 5821 7788

Fax

Internet

+86 10 5821 7618 www.abb.com

ABB ACQ810 Hardware Manual 0-45kW

Hardware manual

List of related manuals

Hardware manual

Safety instructions 5

Safety instructions

What this chapter contains

Use of warnings and notes

6 Safety instructions

Installation and maintenance work

Safety instructions 7

Start-up and operation

8 Safety instructions

Table of contents 9

Table of contents

10 Table of contents

Table of contents 11

12 Table of contents

Table of contents 13

14 Table of contents

About this manual 15

About this manual

What this chapter contains

Compatibility

Intended audience

Categorization according to the frame size

16 About this manual

Categorization according to the + code

Contents

About this manual 17

Installation and commissioning flowchart

18 About this manual

About this manual 19

Terms and abbreviations

20 About this manual

Operation principle and hardware description 21

Operation principle and hardware description

What this chapter contains

The ACQ810-04

22 Operation principle and hardware description

Layout

Drive module, frame size A

JCU Control Unit with cover assembly removed

Operation principle and hardware description 23

Operation principle

Main circuit

Motor control

24 Operation principle and hardware description

Power connections and control interfaces

Operation principle and hardware description 25

Type designation

26 Operation principle and hardware description

Planning the cabinet assembly 27

Planning the cabinet assembly

What this chapter contains

Cabinet construction

Disposition of the devices

28 Planning the cabinet assembly

Grounding of mounting structures

Planning the fastening of the cabinet

Planning the cabinet assembly 29

Main dimensions and free space requirements

30 Planning the cabinet assembly

Cooling and degrees of protection

Planning the cabinet assembly 31

32 Planning the cabinet assembly

Preventing the recirculation of hot air

Cabinet heaters

Mechanical installation 33

Mechanical installation

Contents of the package

34 Mechanical installation

Mechanical installation 35

Delivery check and drive module identification

Before installation

for the allowed operation conditions of the drive. Refer to

36 Mechanical installation

Installation procedure

Direct wall mounting

DIN rail mounting (Frames A and B only)