EN / ACS850-04 (1.1 to 45 kW) Hardware Manual

EN / ACS850-04 (1.1 to 45 kW) Hardware Manual
ACS850
Hardware Manual
ACS850-04 Drive Modules (1.1 to 45 kW)
ACS850-04 Drive Modules
1.1 to 45 kW
Hardware Manual
3AUA0000045496 REV A EN
EFFECTIVE: 3.11.2008
© 2008 ABB Oy. All Rights Reserved.
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.
Safety instructions
6
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.
•
Drives controlling a permanent magnet motor: A rotating permanent magnet
motor feeds power to the drive causing the drive to become live even when it is
stopped and the supply power switched off. Before maintenance work on the
drive,
– disconnect the motor from the drive by using a safety switch
– prevent the start-up of any other motors in the same mechanical system
– lock the motor shaft
– measure that the motor is in fact de-energised, then connect the U2, V2 and
W2 terminals of the drive to each other and to the PE.
•
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:
•
Safety instructions
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–.
7
•
Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V)
may be present on the terminals of the relay output(s) of the drive.
•
The drive supports the “Safe Torque Off” function. See page 38.
WARNING! Ignoring the following instructions can cause physical injury or death, or
damage to the equipment.
•
The drive is not field repairable. Never attempt to repair a malfunctioning drive;
contact your local ABB representative or Authorized Service Center for
replacement.
•
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.
•
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.
Safety instructions
8
Start-up and operation
These warnings are intended for all who plan the operation of the drive, start up or
operate the drive.
WARNING! Ignoring the following instructions can cause physical injury or death,
or damage to the equipment.
•
Before adjusting the drive and putting 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.
•
Drives controlling a permanent magnet motor: Do not run the motor over the
rated speed. Motor overspeed leads to overvoltage which may permanently
damage the drive.
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
and braking resistor, if present) become hot when the system is in use.
Safety instructions
9
Table of contents
Safety instructions
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start-up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
6
8
Table of contents
About this manual
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Categorization according to the frame size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Categorization according to the + code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation and commissioning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
15
15
15
15
15
16
16
16
17
19
Operation principle and hardware description
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power connections and control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
21
21
22
22
22
23
24
Planning the cabinet assembly
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cabinet construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disposition of the devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding of mounting structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main dimensions and free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling and degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventing the recirculation of hot air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
25
25
25
26
26
28
28
Table of contents
10
Inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Cabinet heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Mechanical installation
Contents of the package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Delivery check and drive module identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Requirements for the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direct wall mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIN rail mounting (Frames A and B only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mains choke installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMC filter installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Braking resistor installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
31
31
31
32
32
32
33
33
33
Planning the electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supply connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermal overload and short circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermal overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protection against short-circuit in motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protection against short-circuit in the supply cable or the drive . . . . . . . . . . . . . . . . . . . . . . .
Operating time of the fuses and circuit breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor thermal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground fault protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Torque Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protecting the relay output contacts and attenuating disturbances in case of inductive loads . . . .
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection of a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
35
35
35
35
36
36
36
36
36
36
36
36
37
37
38
39
39
39
40
40
42
42
42
42
42
43
Electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Table of contents
11
Removing the cover assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supply cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Braking resistor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power cable connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power cable connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding the motor cable shield at the motor end . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation of power cable clamp plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power cable connection – frame size A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power cable connection – frame size B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power cable connection – frame sizes C and D (connector covers removed) . . . . . . .
DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation of optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control connections to the JCU Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External power supply for the JCU Control Unit (X1) . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermistor input (X4:8…9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive-to-drive link (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Torque Off (X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding and routing the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45
47
47
47
47
47
48
48
49
50
51
52
53
54
55
57
57
57
58
58
59
59
60
60
61
62
Installation checklist
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Maintenance
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan replacement (Frames A and B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan replacement (Frames C and D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other maintenance actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transferring the memory unit to a new drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The 7-segment display on the JCU Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
67
67
67
67
68
68
69
70
70
70
70
Technical data
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Table of contents
12
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ambient temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling characteristics, noise levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supply cable fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC input (supply) connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JCU Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compliance with EN 61800-3 (2004), category C2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compliance with EN 61800-3 (2004), category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compliance with EN 61800-3 (2004), category C4 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compliance with the Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C-Tick marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product protection in the US . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
72
72
73
73
74
75
75
75
76
77
77
77
78
78
79
80
80
80
80
80
81
81
81
81
82
82
82
Mains chokes
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
When is a mains choke required? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
83
83
83
84
84
EMC filters
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
When is an EMC filter required? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JFI-A1/JFI-B1 (Frame A/B, category C3) installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JFI-A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JFI-B1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JFI-0x (Frames A…D, category C2) installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
85
85
86
87
87
87
88
88
89
90
90
Table of contents
13
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Resistor braking
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Braking choppers and resistors with the ACS850-04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Braking choppers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Braking resistor selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chopper data / Resistor selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resistor installation and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contactor protection of drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Braking circuit commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
91
91
91
91
92
93
93
94
Dimension drawings
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Frame size A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Frame size B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Frame size C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Frame size D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Mains chokes (type CHK-0x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
EMC filters (type JFI-x1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
JFI-A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
JFI-B1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
EMC filters (type JFI-0x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Braking resistors (type JBR-xx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Table of contents
14
Table of contents
15
About this manual
What this chapter contains
This chapter describes the intended audience and contents of this manual. It
contains a flowchart of steps in checking the delivery, installing and commissioning
the drive. The flowchart refers to chapters/sections in this manual and other
manuals.
Compatibility
The manual is compatible with ACS850-04 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.
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.
Product and service inquiries
Address any inquiries about the product to your local ABB representative, quoting
the type code and serial number of the unit in question. A listing of ABB sales,
support and service contacts can be found by navigating to www.abb.com/drives and
selecting Drives – Sales, Support and Service network.
About this manual
16
Product training
For information on ABB product training, navigate to www.abb.com/drives and select
Drives – 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).
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, provisions for fulfilling the requirements for CE
and other markings and warranty policy.
Mains chokes details the optional mains chokes available for the drive.
EMC filters details the EMC filtering options available for the drive.
Resistor braking describes how to select, protect and wire braking resistors.
Dimension drawings contains the dimensional drawings of the drive and connected
equipment.
About this manual
17
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 71)
Plan the installation.
Planning the cabinet assembly (page 25)
Check the ambient conditions, ratings, required
Planning the electrical installation (page 35)
cooling air flow, input power connection, compatibility
Technical data (page 71)
of the motor, motor connection, and other technical
data.
Option manual (if optional equipment is
included)
Select the cables.
Unpack and check the units.
Check that all necessary optional modules and
equipment are present and correct.
Only intact units may be started up.
Check the installation site.
Mechanical installation: Contents of the
package (page 29)
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.
Mechanical installation: Before installation
(page 31)
Technical data (page 71)
If the drive is about to be connected to an IT
Safety instructions: Installation and
(ungrounded) system, check that the screws labelled maintenance work (page 6)
VAR and EMC (1 and 2, if present) are removed. Also
note that using an EMC filter is not allowed in an IT
(ungrounded] system.
Install the drive in a cabinet.
Mechanical installation: Installation procedure
(page 32)
Route the cables.
Planning the electrical installation: Routing the
cables (page 42)
Check the insulation of the supply cable, the motor
and the motor cable, and the resistor cable (if
present).
Electrical installation: Checking the insulation of
the assembly (page 47)
About this manual
18
Task
Connect the power cables.
Connect the control and the auxiliary control cables.
See
Electrical installation: Power cable connection:
(page 48) and Connecting the control cables:
(page 58)
For optional equipment:
Mains chokes (page 83)
EMC filters (page 85)
Resistor braking (page 91)
Manuals for any optional equipment
Check the installation.
Installation checklist (page 65)
Commission the drive.
Appropriate Firmware Manual
Commission the braking chopper if required.
Resistor braking (page 91)
Operating of the drive: start, stop, speed control etc.
Appropriate Firmware Manual
About this manual
19
Terms and abbreviations
Term/Abbreviation
Explanation
CHK-xx
Series of optional mains chokes for the ACS850.
EMC
Electromagnetic Compatibility.
FIO-01
Optional digital I/O extension for the ACS850.
FIO-11
Optional analog I/O extension for the ACS850.
FIO-21
Optional analog/digital I/O extension for the ACS850.
FEN-01
Optional TTL encoder interface for the ACS850.
FEN-11
Optional absolute encoder interface for the ACS850.
FEN-21
Optional resolver interface for the ACS850.
FEN-31
Optional HTL encoder interface for the ACS850.
FCAN-0x
Optional CANopen adapter for the ACS850.
FDNA-0x
Optional DeviceNet adapter for the ACS850.
FENA-0x
Optional Ethernet/IP adapter for the ACS850.
FLON-0x
Optional LONWORKS® adapter for the ACS850.
FMBA-0x
Optional Modbus adapter for the ACS850.
FPBA-0x
Optional PROFIBUS DP adapter for the ACS850.
Frame (size)
Size of the drive module. This manual deals with ACS850-04 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.
IGBT
Insulated Gate Bipolar Transistor; a voltage-controlled semiconductor type
widely used in inverters due to their easy controllability and high switching
frequency.
I/O
Input/Output.
JBR-xx
Series of optional braking resistors for the ACS850.
JCU
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.
JFI-xx
Series of optional EMC filters for the ACS850.
JMU
The memory unit attached to the control unit of the drive.
RFI
Radio-frequency interference.
About this manual
20
About this manual
21
Operation principle and hardware description
What this chapter contains
This chapter describes the operating principle and construction of the ACS850-04
drive module in short.
Operation principle
Main circuit
The main circuit of the drive module is shown below.
AC supply
CHK-xx mains choke (see chapter Mains chokes
on page 83)
UDC+ UDC-
U1 V1 W1
ACS850-04
JFI-xx EMC filter (see chapter EMC filters on page
85)
~
=
+
Rectifier
–
Capacitor bank
=
Inverter
~
U2 V2 W2
Braking chopper
R-
R+
Motor output
JBR-xx braking resistor (optional)
Component
Description
Braking chopper
Conducts the energy generated by a decelerating motor from the DC bus to a
braking resistor. The braking chopper is built in the ACS850-04; braking
resistors are external options.
Braking resistor
Dissipates the regenerative energy by converting it to heat.
Capacitor bank
Energy storage which stabilizes the intermediate circuit DC voltage.
Inverter
Converts the DC voltage to AC voltage and vice versa. The motor is controlled
by switching the IGBTs of the inverter.
Mains choke
See page 83.
EMC filter
See page 85.
Rectifier
Converts the three-phase AC voltage to DC voltage.
Operation principle and hardware description
22
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.
Product overview
The ACS850-04 is an air-cooled IP20 drive module for controlling AC motors. It is to
be installed into a cabinet by the customer.
The ACS850-04 is available in several frame sizes depending on output power. All
frame sizes use the same control unit (type JCU).
Layout
Drive module, frame size A
JCU Control Unit with cover
assembly removed
DC connection
AC supply connection
7-segment display
Power unit
JCU Control Unit with
optional cover
assembly
External 24 V power
input
Relay output
Digital inputs/outputs
Analog inputs
Slots 1 and 2 for
optional I/O extensions
and encoder/resolver
interface
Thermistor input
Analog outputs
Drive-to-drive link
Slot 3 for optional
fieldbus adapter
Safe Torque Off
connection
Control panel/PC
connection
Motor and braking
resistor connections
Operation principle and hardware description
Memory unit (JMU)
connection
23
Power connections and control interfaces
The diagram shows the power connections and control interfaces of the drive.
Control unit (JCU)
Slot 1 / Slot 2
FIO-01 (Digital I/O
extension)
FIO-11 (Analog I/O
extension)
FIO-31 (Digital/Analog I/O
extension)
FEN-01 (Incremental [TTL]
encoder interface)
FEN-11 (Absolute encoder
interface)
FEN-21 (Resolver interface)
FEN-31 (Incremental [HTL]
encoder interface)
Note: No two
encoder/resolver interfaces
of the same type can be
connected at a time
Slot 3 (Fieldbus adapter)
FCAN-0x (CANopen)
FDNA-0x (DeviceNet)
FENA-0x (Ethernet/IP)
FLON-01 (LONWORKS®)
FMBA-01 (Modbus)
FPBA-0x (PROFIBUS DP)
Fxx
7-segment
status display 2)
2)
See page 70.
Slot 1
Fxx
Slot 2
Control panel or PC
Fxxx
Memory unit 2)
Slot 3
External power input
*Relay output
*Digital inputs and outputs
(9 pcs)
*Analog inputs and outputs
(6 pcs)
Drive-to-drive link
Safe Torque Off
X1
X2
X3
For more information on these
connections, see page 58. For
specifications, see page 76.
*Programmable
X4
X5
X6
Power unit
3-phase power
supply
PE
L1
PE
U1
L2
V1
L3
W1
U2
R-
Braking resistor (optional)
V2
Braking
chopper
UDC+
UDCR+
W2
M
3~
AC motor
t°
Operation principle and hardware description
24
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. ACS850-0404A8-4). The optional selections are given thereafter, preceded by + signs (e.g.
+L501). The main selections are described below. Not all selections are necessarily
available for all types; refer to ACS850 Ordering Information, available on request.
See also section Delivery check and drive module identification on page 31.
Selection
Product series
Type
Size
Voltage range
+ options
Filters
Alternatives
ACS850 product series
04
Drive module. When no options are selected: IP20 (UL Open Type), plain
front cover, no control panel, no mains choke (frames A and B), internal
mains choke (frames C and D), no EMC filter, internal braking chopper,
coated boards, Safe Torque Off, Quick Installation Guides (multilingual),
CD containing all manuals
Refer to Technical data: Ratings.
5
380…500 V
E...
Control panel and front
cover options
J...
Fieldbus
K...
I/O extensions and
feedback interfaces
L...
Programs
N...
+E200: EMC filter, C3, 2nd Environment, Unrestricted (Earthed network)
(External with frames A and B, internal with frames C and D)
+0C168: No drive module front cover, no control panel
+J400: Control panel mounted on drive module front cover
+J410: Control panel with door mounting platform kit including 3 m cable
+J414: Control panel mounting platform on drive module (no control
panel included)
+K451: FDNA-01 DeviceNet adapter
+K454: FPBA-01 PROFIBUS DP adapter
+K457: FCAN-01 CANopen adapter
+K466: FENA-01 Ethernet/IP adapter
+K458: FMBA-01 Modbus adapter
+K452: FLON-01 LONWORKS® adapter
+L500: FIO-11 analog I/O extension
+L501: FIO-01 digital I/O extension
+L502: FEN-31 HTL encoder interface
+L516: FEN-21 resolver interface
+L517: FEN-01 TTL encoder interface
+L518: FEN-11 absolute encoder interface
+L519: FIO-21 analog/digital I/O extension
+N697: Crane control program
00579470
Operation principle and hardware description
25
Planning the cabinet assembly
What this chapter contains
This chapter guides in planning the installation of a drive module into a user-defined
cabinet. The issues discussed are essential for safe and trouble-free use of the drive
system.
Note: 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.
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 cabinet assembly
26
Main dimensions and free space requirements
The modules can be installed side by side. The dimensions of the drive modules are
presented in chapter Dimension drawings (page 95). The free space requirements
are shown below.
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 103.)
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, mains chokes and braking resistors) 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.
Planning the cabinet assembly
27
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.
Planning the cabinet assembly
28
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.
Planning the cabinet assembly
29
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.
Mechanical installation
30
The box contains:
• ACS850-04 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
• EMC filter (+E200) if ordered (with frames A and B only)
• control panel mounting kit (+J410) if ordered
• Printed Quick Guides, manuals CD.
Compartments for
cable clamp plates
EMC/RFI filter, control panel
mounting kit
(Underneath the drive module –
lift out the module and open
left-hand side flap to access)
Compartment for
terminal blocks and
CDs
ACS850-04 drive module
Mechanical installation
31
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 24)
Frame size
Ratings
Compliance
markings
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
Check the installation site according to the requirements below. Refer to Dimension
drawings for frame details.
Requirements for the installation site
See Technical data for the allowed operation conditions of the drive.
The ACS850-04 is to be mounted in an upright position. The wall the drive is to be
mounted on must be as even as possible, of non-flammable material and strong
enough to carry the weight of the drive. The floor/material below the drive must be
non-flammable.
Mechanical installation
32
Installation procedure
Direct wall mounting
1. Mark the locations for the four holes. The mounting points are shown in
Dimension drawings.
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
b
1
2
Mechanical installation
33
Mains choke installation
See the chapter Mains chokes on page 83.
EMC filter installation
See the chapter EMC filters on page 85.
Braking resistor installation
See the chapter Resistor braking on page 91.
Mechanical installation
34
Mechanical installation
35
Planning the electrical installation
What this chapter contains
This chapter contains the instructions that you must follow when selecting the motor,
cables, protections, cable routing and way of operation for the drive. If the
recommendations given by ABB are 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.
Only one permanent magnet synchronous motor can be connected to the inverter
output. It is recommended to install a safety switch between the permanent magnet
motor and the drive output in order to isolate the motor from the drive during
maintenance work on the drive.
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.
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)
Planning the electrical installation
36
• 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 short-circuit 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
Planning the electrical installation
37
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.
The ACS850-04 has a dedicated connection for PTC or KTY84 sensors. See page
60 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.
Planning the electrical installation
38
Safe Torque Off
The drive supports the Safe Torque Off function according to standards
prEN 61800-5-2; EN 954-1 (1997); IEC/EN 60204-1: 1997; EN 61508: 2002 and
EN 1037: 1996.
The Safe Torque Off function disables the control voltage of the power
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 nonelectrical parts of the machinery can be performed without switching off the power
supply to the drive.
ACS850-04
X6:1
+24 V
X6:2
Safe Torque Off
connection on JCU
Activation
switch
X6:3
X6:4
UDC+
Control
circuit
Output stage
(1 phase shown)
U2/V2/W2
Notes:
UDC-
• 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.
For further information on the function, refer to Safe Torque Off Function, Application
Guide (3AFE68929814 [English]).
Planning the electrical installation
39
Selecting the power cables
General rules
Dimension the supply (input power) and motor cables according to local
regulations.
• The cable must be able to carry the drive load current. See the chapter Technical
data for the rated currents.
• The cable must be rated for at least 70 °C (US: 75 °C [167 °F]) maximum
permissible temperature of conductor in continuous use.
• The conductivity of the PE conductor must be equal to that of a phase conductor
(ie. same cross-sectional area).
• 600 VAC cable is accepted for up to 500 VAC.
• 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. 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.
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
PE conductor
and shield
Note: A separate PE conductor is required if the
conductivity of the cable shield is not sufficient for the
purpose.
Shield
Shield
PE
PE
Shield
Allowed for supply cabling
A four-conductor system: three phase conductors and
a protective conductor.
PE
PE
Planning the electrical installation
40
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.
Insulation jacket
Copper wire screen
Helix of copper tape
Inner insulation
Cable core
Protecting the relay output contacts and attenuating disturbances in case
of inductive loads
Inductive loads (relays, contactors, motors) cause voltage transients when switched
off.
The relay output on the drive is protected with varistors (250 V) against 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.
Planning the electrical installation
41
Install the protective component as close to the inductive load as possible, not at the
relay output.
Varistor
230 VAC
Relay output
RC filter
230 VAC
Relay output
Diode
Relay output
24 VDC
Planning the electrical installation
42
Selecting the control cables
It is recommended that all control cables be shielded.
Double-shielded twisted pair cable is recommended for analogue 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
analogue signals.
Double-shielded cable is the best alternative for low-voltage digital signals but
single-shielded twisted multipair cable (Figure b) is also usable.
a
Double-shielded twisted
pair cable
b
Single-shielded twisted
multipair cable
Run analogue 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 VDC and 115/230 VAC 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 60.
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.
Planning the electrical installation
43
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
Supply cable
min 200 mm (8”)
90°
Drive
Motor cable
min 300 mm (12”)
Control cables
min 500 mm (20”) Braking resistor cable
90°
Motor cable
90°
min 500 mm (20”)
Control cable ducts
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.
24 V
230 V
Lead 24 V and 230 V control
cables in separate ducts inside
the cabinet.
Planning the electrical installation
44
Planning the electrical installation
45
Electrical installation
What this chapter contains
This chapter describes the electrical installation procedure of the drive.
WARNING! The work described in this chapter may only be carried out by a qualified
electrician. Follow the Safety instructions on the first pages 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).
• 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.
Electrical installation
46
2
1
4
3
5
Electrical installation
47
Checking the insulation of the assembly
Drive
Do not make any voltage tolerance or insulation resistance tests (e.g. hi-pot or
megger) on any part of the drive as testing can damage the drive. Every drive has
been tested for insulation between the main circuit and the 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 10 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.
U1
V1
ohm
W1
M
3~
PE
Braking resistor assembly
Check the insulation of the braking resistor assembly (if present) as follows:
1. Check that the resistor cable is connected to the resistor, and disconnected from
the drive output terminals R+ and R-.
2. At the drive end, connect the R+ and R- conductors of the resistor cable together.
Measure the insulation resistance between the combined conductors and the PE
conductor by using a measuring voltage of 1 kV DC. The insulation resistance
must be higher than 1 Mohm.
R+
R-
ohm
PE
Electrical installation
48
Power cable connection
Power cable connection diagram
For alternatives, see Planning the electrical
installation: Supply disconnecting device
(page 35).
L1
L2
L3
(PE)
(PE)
1)
2)
CHK-xx mains choke (optional). See the chapter
Mains chokes (page 83).
JFI-xx EMC filter (optional). See the chapter
EMC filters (page 85).
The UDC+/UDC– connectors can be used for
common DC configurations. See page 55.
ACS850-04
UDC+ UDC–
U2
V2
U1
W2
V1
R–
W1
PE
R+
3)
Optional braking resistor
(see the chapter Resistor
braking [page 91])
V1
U1
W1
~
Motor
3
PE
Notes:
– If shielded supply (input) cable is used, and the conductivity of the shield is less than 50% of the conductivity of a phase conductor, 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 less than 50%
of the conductivity of a phase conductor and the cable has no symmetrical ground conductors. See also
section Selecting the power cables on page 39.
Electrical installation
49
Procedure
Cabling drawings with tightening torques for each frame size are presented on
pages 52 to 54.
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, disconnect the
internal varistors by removing the screw labelled VAR, EMC1 (frames C and D
only) and EMC2 (frames C and D only). The screws are located close to the
supply terminals on the power unit.
WARNING! If a drive whose varistors 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
of the drive. This may cause danger or damage the drive.
If a drive whose varistors 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 51), 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.
Connect the conductors of the resistor cable (if present) to the R+ and R–
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]).
Electrical installation
50
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.
b > 1/5 · a
a
Electrical installation
b
51
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)
Electrical installation
52
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)
0.5 … 0.6 N·m (4.4 … 5.3 lbf·in)
1.5 N·m (13 lbf·in)
Above cable clamp, cover bare
shield with insulating tape
Cable clamp on bare shield
1.5 N·m (13 lbf·in)
Motor cable
Electrical installation
Braking resistor cable
53
Power cable connection – frame size B
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)
U1
V1
W1
1.2 … 1.5 N·m (10.6 … 13.3 lbf·in)
U2
V2
W2
R-
R+
1.5 N·m (13 lbf·in)
Above cable clamp, cover bare
shield with insulating tape
Cable clamp on bare shield
1.5 N·m (13 lbf·in)
Motor cable
Braking resistor cable
Electrical installation
54
Power cable connection – frame sizes C and D (connector covers removed)
Supply
cable
Screw lug detail
Below cable clamp, cover bare
shield with insulating tape
Cable clamp on bare shield
1.5 N·m (13 lbf·in)
15 N·m (11 lbf·ft)
3 N·m
(25 lbf·in)
15 N·m
(11 lbf·ft)
3 N·m
(25 lbf·in)
U1
U2
V2
W2
V1
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.
W1
R-
R+
3 N·m
(25 lbf·in)
15 N·m
(11 lbf·ft)
3 N·m
(25 lbf·in)
Cable clamp on
bare shield
1.5 N·m
(13 lbf·ft)
Motor cable
Electrical installation
Direct lug connection
Above cable clamp,
cover bare shield with
insulating tape
Braking resistor cable
55
DC connection
The UDC+ and UDC– terminals are intended for common DC configurations of a
number of ACS850 drives, allowing regenerative energy from one drive to be utilised
by the other drives in motoring mode.
One or more drives are connected to the AC supply depending on 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–
M
3~
UDC+
~
~
UDC–
M
3~
~
M
3~
AC supply
Mains chokes
UDC+
~
UDC–
M
3~
UDC+
~
~
UDC–
M
3~
UDC+
~
~
UDC–
~
M
3~
Electrical installation
56
Each drive has an independent DC capacitor pre-charging circuit.
UDC+ UDC-
U1 V1 W1
ACS850-04
~
=
+
–
Pre-charging circuit
=
~
U2 V2 W2
The ratings of the DC connection are given on page 75.
Electrical installation
57
Installation of optional modules
Optional modules such as fieldbus adapters, I/O extensions and encoder interfaces
are inserted into slots on the JCU Control Unit. See page 23 for the available slots.
Mechanical installation
• Remove the cover assembly from on the JCU Control Unit (refer to page 45).
• 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 58. See the
appropriate option manual for specific installation and wiring instructions.
Electrical installation
58
Connecting the control cables
Control connections to the JCU Control Unit
X1
Notes:
*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.
External power input
24 V DC, 1.6 A
+24VI
GND
1
2
Relay output
250 V AC / 30 V DC
2A
NO
COM
NC
1
2
3
+24 V DC*
Digital I/O ground
Digital input 1
Digital input 2
+24 V DC*
Digital I/O ground
Digital input 3
Digital input 4
+24 V DC*
Digital I/O ground
Digital input 5
Digital input 6
+24 V DC*
Digital I/O ground
Digital input/output 1
Digital input/output 2
+24 V DC*
Digital I/O ground
Digital input/output 3
+24VD
DGND
DI1
DI2
+24VD
DGND
DI3
DI4
+24VD
DGND
DI5
DI6
+24VD
DGND
DIO1
DIO2
+24VD
DGND
DIO3
Reference voltage (+)
Reference voltage (–)
Ground
Analogue input 1 (Current or voltage, selectable
by jumper J1)
Analogue input 2 (Current or voltage, selectable
by jumper J2)
AI1 current/voltage selection
AI2 current/voltage selection
Thermistor input
Ground
Analogue output 1 (current)
Analogue output 2 (voltage)
Ground
+VREF
-VREF
AGND
AI1+
AI1AI2+
AI2-
X2
Wire sizes and tightening torques:
2
X2: 0.5 … 2.5 mm (24…12 AWG).
Torque: 0.5 N·m (5 lbf·in)
X3, X4, X5, X6:
0.5 … 1.5 mm2 (28…14 AWG).
Torque: 0.3 N·m (3 lbf·in)
Order of terminal headers and
jumpers
X1 (2-pole)
X2 (3-pole)
X3 (4 × 4-pole,
1 × 3-pole)
X4 (1 × 7-pole,
1 × 2-pole,
1 × 3-pole)
Drive-to-drive link termination
Drive-to-drive link.
B
A
BGND
Safe Torque Off. Both circuits must be closed for
the drive to start.
OUT1
OUT2
IN1
IN2
J1
J2
J3
X5 (3-pole)
X6 (4-pole,
orange)
Electrical installation
TH
AGND
AO1 (I)
AO2 (U)
AGND
Control panel connection
Memory unit connection
X3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
X4
1
2
3
4
5
6
7
J1
J2
8
9
10
11
12
X5
J3
1
2
3
X6
1
2
3
4
X7
X205
T
59
Jumpers
J1 – Determines whether Analogue input AI1 is used as a current or voltage input.
Current
Voltage
7
AI1
AI2
8
7
AI1
AI2
8
J2 – Determines whether Analogue input AI2 is used as a current or voltage input.
Current
Voltage
7
AI1
AI2
8
7
AI1
AI2
8
J3 – 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 (X1)
External +24 V (minimum 1.6 A) power supply for the JCU Control Unit can be
connected to terminal block X1. 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.
Electrical installation
60
Thermistor input (X4:8…9)
Motor temperature can be measured using PTC or KTY84 sensors connected to the
thermistor input.
One PTC or KTY84 sensor
Three PTC sensors
TH
TH
Motor
Motor
AGND
AGND
T
10 nF
T
T
T
10 nF
WARNING! As the thermistor input on the JCU Control Unit is not insulated
according to IEC 60664, the connection of the motor temperature sensor requires
double or reinforced insulation between motor live parts and the sensor. If the
assembly does not fulfil the requirement,
• the I/O board terminals 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.
Drive-to-drive link (X5)
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 J3 (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 62.
Electrical installation
61
Termination ON
JCU
Drive 1
Termination OFF
JCU
Drive 2
BGND 3
A 2
B 1
T
BGND 3
A 2
X5:D2D
...
J3
X5:D2D
J3
J3
X5:D2D
B 1
T
BGND 3
A 2
B 1
T
The following diagram shows the wiring of the drive-to-drive link.
Termination ON
JCU
Drive n
Safe Torque Off (X6)
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 38.
Electrical installation
62
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 going to the optional modules on the
control unit through the cover mounting bracket. The cables going to the terminal
blocks on the control unit are to be run along the right-hand side of the drive module.
See the drawings 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
high-frequency 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.
Before re-installing the cover assembly, remove the appropriate punch-outs on the
right side of the cover base to create entries for the control cables going to the
terminal blocks.
Re-install the cover assembly according to the instructions on page 45.
Electrical installation
63
Mounting the clamp plate
Routing the control cables
Use shrink tubing or tape to
contain strands
0.7 N·m
(6.2 lbf·in)
Run cables going to optional
modules through the cover
mounting bracket
1.5 N·m
(13 lbf·in)
Remove outer jacket of
cable at clamp to
expose cable shield
Electrical installation
64
Electrical installation
65
Installation checklist
Checklist
Check the mechanical and electrical installation of the drive before start-up. Go
through the checklist below together with another person. Read the Safety
instructions on the first pages of this manual before you work on the unit.
Check
MECHANICAL INSTALLATION
The ambient operating conditions are allowable. (See Mechanical installation, Technical data:
Ratings, Ambient conditions.)
The unit is fastened properly to the cabinet. (See Planning the cabinet assembly 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, EMC1 (frames C and D only) and EMC2 (frames C and D only) 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.
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 braking resistor (if present) is connected to R+/R-, and the terminals are tightened to
specified torque.
The motor cable (and braking resistor cable, if present) 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.
Installation checklist
66
Check
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.
Installation checklist
67
Maintenance
What this chapter contains
This chapter contains preventive maintenance instructions.
Safety
WARNING! Read the Safety instructions on the first pages of this manual before
performing any maintenance on the equipment. Ignoring the safety instructions can
cause injury or death.
Maintenance intervals
If installed in an appropriate environment, the drive requires very little maintenance.
This table lists the routine maintenance intervals recommended by ABB.
Interval
Maintenance
Instruction
Every year of storage
Capacitor reforming
See Reforming the
capacitors.
Depends on the dustiness of the environment
(every 6 to 12 months)
Heatsink temperature
check and cleaning
See Heatsink.
Every 6 years if the ambient temperature does
not exceed 40 °C (104 °F).
Every 3 years if the ambient temperature is
higher than 40 °C (104 °F).
Cooling fan change
See Cooling fan.
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. Replace the cooling fan.
Maintenance
68
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 direct
io
Maintenance
n
69
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 direct
io
n
Maintenance
70
Reforming the capacitors
The capacitors must be reformed if the drive has been stored for a year or more. See
page 31 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 may
take a few moments; the LED display will read “L” while copying is in progress.
The 7-segment display on the JCU Control Unit
The following table describes the indications given by the 7-segment display on the
JCU Control Unit. Multi-character indications are displayed as repeated sequences
of characters.
Display
L
Meaning
Loading application program or data from the memory unit. This is the normal
display immediately after powering up the drive.
Normal operation – drive stopped.
(Rotating display) Normal operation – drive running.
“E” followed by
System error.
four-digit error code 9001, 9002 = Control unit hardware failure.
9003 = No memory unit connected.
9004 = Memory unit failure.
9007, 9008 = Loading of firmware from memory unit failed.
9009…9018 = Internal error.
9019 = Contents of memory unit corrupted.
9020 = Internal error.
9021 = Program versions of memory unit and drive incompatible.
9102…9108 = Internal error.
“A” followed by
Alarm generated by the application program. For error codes, see the Firmware
four-digit error code Manual.
“F” followed by
Fault generated by the application program. For error codes, see the Firmware
four-digit error code Manual.
Maintenance
71
Technical data
What this chapter contains
This chapter contains the technical specifications of the drive, e.g. the ratings, sizes
and technical requirements, and provisions for fulfilling the requirements for CE and
other markings.
Ratings
The nominal current ratings for the ACS850-04 with 500 V AC supply are given
below.
Input ratings
Drive type Frame
ACS850-04… size
-03A0-5
-03A6-5
-04A8-5
-06A0-5
-08A0-5
-010A-5
-014A-5
-018A-5
-025A-5
-030A-5
-035A-5
-044A-5
-050A-5
-061A-5
-078A-5
-094A-5
A
A
A
A
A
B
B
B
C
C
C
C
C
D
D
D
I1N
*I1N
A
2.3
3.1
4.0
5.5
6.6
8.7
12
16
20
26
30
36
42
55
65
82
A
4.0
6.0
7.0
9.0
11
13
18
23
–
–
–
–
–
–
–
–
Nominal
I2N
IMax
A
3.0
3.6
4.8
6.0
8.0
10.5
14
18
25
30
35
44
50
61
78
94
A
4.4
5.3
7.0
8.8
10.5
13.5
16.5
21
33
36
44
53
66
78
100
124
Output ratings
No-overload use Light-overload use
PN
ILd
PLd
PLd
kW
1.1
1.5
2.2
2.2
3.0
4.0
5.5
7.5
11.0
15.0
18.5
22
22
30
37
45
HP
1.5
2.0
3.0
3.0
5.0
5.0
7.5
10
15
20
25
30
30
40
50
60
A
2.8
3.4
4.5
5.5
7.6
9.7
13.0
16.8
23
28
32
41
46
57
74
90
kW
1.1
1.5
1.5
2.2
3.0
4.0
5.5
7.5
11
15
15
22
22
30
37
45
HP
1.0
2.0
2.0
3.0
5.0
5.0
7.5
10
15
20
20
30
30
40
50
60
Heavy-duty use
IHd
PHd
PHd
A
2.5
3.0
4.0
5.0
6.0
9.0
11.0
14.0
19.0
24
29
35
44
52
69
75
kW
0.75
1.1
1.5
2.2
2.2
4.0
5.5
7.5
7.5
11.0
15.0
18.5
22
22
37
37
HP
1.0
1.5
2.0
3.0
3.0
5.0
7.5
10
10
15
20
25
30
40
50
50
581898
I1N
Nominal input current (rms) at 40 °C (104 °F).
*Without mains choke.
I2N
Nominal output current.
IMax Maximum output current. Available for 10 seconds at start, otherwise as long as allowed by drive temperature.
PN
Continuous rms output current. No overload capability at 40 °C (104 °F).
ILd
Continuous rms output current. 10% overload is allowed for 1 minute every 5 minutes.
PLd
Typical motor power.
IHd
Continuous rms output current. 50% overload is allowed for 1 minute every 5 minutes.
PHd Typical motor power.
Note: Frame sizes C and D can be used continuously without a mains choke at up to 50% of nominal shaft power (i.e.
at continuous nominal torque up to 50% of rated speed).
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 for the required motion profile.
Technical data
72
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
Ambient temperature
+40 °C
+104 °F
+55 °C
+131 °F
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.
Technical data
73
Dimensions and weights
See also chapter Dimension drawings on page 95.
Frame
size
A
B
C
D
Height (without
cable clamp
plates)
mm (in.)
364 (14.33)
380 (14.96)
567 (22.32)
567 (22.32)
Height (with
cable clamp
plates)
mm (in.)
474 (18.66)
476 (18.74)
658 (25.91)
744 (29.29)
Width
mm (in.)
93.5 (3.68)
101 (3.98)
166 (6.54)
221 (8.70)
Depth
(without control
panel )
mm (in.)
197 (7.76)
274 (10.79)
276 (10.87)
276 (10.87)
Depth
(with control
panel)
mm (in.)
222 (8.74)
300 (11.81)
301 (11.85)
301 (11.85)
Weight
kg (lbs)
3.2 (7.1)
5.4 (11.9)
15.6 (34.4)
21.3 (47)
Cooling characteristics, noise levels
Drive type
ACS850-04xx…
-03A0-5
-03A6-5
-04A8-5
-06A0-5
-08A0-5
-010A-5
-014A-5
-018A-5
-025A-5
-030A-5
-035A-5
-044A-5
-050A-5
-061A-5
-078A-5
-094A-5
Power loss
W (BTU/h)
100 (342)
106 (362)
126 (430)
148 (505)
172 (587)
212 (725)
250 (855)
318 (1085)
375 (1280)
375 (1280)
485 (1660)
541 (1850)
646 (2210)
840 (2870)
1020 (3480)
1200 (4100)
Air flow
m3/h (ft3/min)
24 (14)
24 (14)
24 (14)
24 (14)
24 (14)
48 (28)
48 (28)
48 (28)
142 (84)
142 (84)
142 (84)
200 (118)
200 (118)
290 (171)
290 (171)
290 (171)
Noise level
dBA
47
47
47
47
47
39
39
39
63
63
63
71
71
70
70
70
Technical data
74
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 Planning the electrical installation.
Note: Fuses with a higher current rating must not be used.
Drive type
ACS850-04xx…
-03A0-5
-03A6-5
-04A8-5
-06A0-5
-08A0-5
-010A-5
-014A-5
-018A-5
-025A-5
-030A-5
-035A-5
-044A-5
-050A-5
-061A-5
-078A-5
-094A-5
*Without mains choke
Technical data
Input
current
(A)
4.0*
6.0*
7.0*
9.0*
11*
13*
18*
23*
20
26
30
36
42
55
65
82
IEC fuse
Rated
current
(A)
6
6
10
10
16
16
20
25
25
32
40
50
50
63
80
100
Voltage
(V)
500
500
500
500
500
500
500
500
500
500
500
500
500
500
500
500
Cross-sectional
area of cable
UL fuse
Class
gG
gG
gG
gG
gG
gG
gG
gG
gG
gG
gG
gG
gG
gG
gG
gG
Rated
current
(A)
6
6
10
10
15
15
20
25
25
35
35
45
50
70
80
100
Voltage
(V)
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
600
UL
Class
mm2
AWG
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
T
1.5 … 4
1.5 … 4
1.5 … 4
1.5 … 4
1.5 … 4
1.5 … 10
1.5 … 10
1.5 … 10
6…35
6…35
6…35
6…35
10…70
10…70
10…70
10…70
16…12
16…12
16…12
16…12
16…12
16…8
16…8
16…8
9…2
9…2
9…2
9…2
6 … 2/0
6 … 2/0
6 … 2/0
6 … 2/0
75
AC input (supply) connection
Voltage (U1)
Frequency
Network type
Imbalance
Fundamental power factor
(cos phi1)
Terminals
380 … 500 V AC +10%/-15%, 3-phase
50 … 60 Hz ±5%
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 mm2 wire.
Frame B: Detachable screw terminal block for 0.5 … 6 mm2 wire.
Frames C and D: Screw lugs for 6…70 mm2 wire included. Suitable crimp lugs can be
used instead.
DC connection
Voltage
Ratings, fuse
recommendations
436 … 743 V DC
-03A0-5
-03A6-5
-04A8-5
-06A0-5
-08A0-5
-010A-5
-014A-5
-018A-5
-025A-5
-030A-5
-035A-5
-044A-5
-050A-5
-061A-5
-078A-5
-094A-5
IdcN
C
Terminals
IdcN
C
(A)
3.3
3.9
4.8
6.5
8.7
12
15
20
29
38
44
54
54
73
85
98
(µF)
120
120
240
240
240
370
740
740
670
670
1000
1000
1000
1340
2000
2000
Drive type
ACS850-04xx…
IEC fuse
UL fuse
Rated
Rated
current Voltage
current Voltage
(A)
(V)
Class
(A)
(V)
Class
10
10
10
16
16
20
25
32
TBA
40
50
50
63
63
80
100
125
Average DC input current requirement when running a typical induction motor
at PN at a DC link voltage of 540 V (which corresponds to an AC input voltage
of 400 V).
Capacitance of DC link.
Frame A: Detachable screw terminal block for 0.25 … 4 mm2 wire.
Frame B: Detachable screw terminal block for 0.5 … 6 mm2 wire.
Frames C and D: Screw lugs for 6…70 mm2 wire included. Suitable crimp lugs can be
used instead.
Motor connection
Motor types
Frequency
Asynchronous induction motors, asynchronous servo motors, synchronous permanent
magnet motors, permanent magnet servo motors
0 … 500 Hz
Technical data
76
Current
Switching frequency
Maximum motor cable
length
Terminals
See section Ratings.
3 kHz (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
Frame A: Detachable screw terminal block for 0.25 … 4 mm2 wire.
Frame B: Detachable screw terminal block for 0.5 … 6 mm2 wire.
Frames C and D: Screw lugs for 6…70 mm2 wire included. Suitable crimp lugs can be
used instead.
JCU Control Unit
Power supply
Relay output (X2)
Digital inputs DI1…DI6 (X3)
Digital inputs/outputs
DIO1…DIO3 (X3).
24 V (±10%) DC, 1.6 A
Supplied from the power unit of the drive, or from external power supply through connector
X1 (pitch 3.5 mm, wire size 1.5 mm2).
Connector pitch 5 mm, wire size 2.5 mm2
250 V AC / 30 V DC, 2 A
Protected by varistors
Connector pitch 3.5 mm, wire size 1.5 mm2
24 V logic levels: “0” < 5 V, “1” > 15 V
Rin: 2.0 kohm
Filtering: Adjustable, 0.25 ms min. (see also Firmware Manual)
Connector pitch 3.5 mm, wire size 1.5 mm2
As inputs:
Input/output mode selection by 24 V logic levels: “0” < 5 V, “1” > 15 V
Rin: 2.0 kohm
parameters.
Filtering:
Adjustable, 0.25 ms min. (see also Firmware Manual)
DIO2 can be configured as a
frequency input (3…32 kHz)
for 24 V level square wave
signal (sinusoidal or other
wave form cannot be used).
DIO3 can be configured as a
24 V level square wave
frequency output. See
Firmware Manual, parameter
group 12.
As outputs:
Total output current limited by auxiliary voltage outputs to 200 mA
Output type: Open emitter
VCC
DIOx
RL
DGND
Analogue inputs AI1 and AI2 Connector pitch 3.5 mm, wire size 1.5 mm2
Current input: –20…20 mA, Rin: 100 ohm
(X4).
Voltage input: –10…10 V, Rin: 200 kohm
Current/voltage input mode
Differential inputs, common mode ±20 V
selection by jumpers. See
Sampling interval per channel: 0.25 ms
page 59.
Filtering: Adjustable, 0.25 ms min. (see also Firmware Manual)
Resolution: 11 bit + sign bit
Inaccuracy: 1% of full scale range
Thermistor input (X4)
Connector pitch 3.5 mm, wire size 1.5 mm2
Input devices: PTC or KTY84 thermistor
Up to three PTCs can be connected in series
KTY84 thermistor: Inaccuracy 5 °C
No safety insulation (see page 60)
Technical data
77
Analogue outputs AO1 and
AO2 (X4)
Reference voltage (VREF)
for analogue inputs
Drive to drive link (X5)
Safe Torque Off connection
(X6)
Control panel / PC
connection (X7)
Connector pitch 3.5 mm, wire size 1.5 mm2
AO1 (current): 0…20 mA, Rload < 500 ohm
AO2 (voltage): –10…10 V, Rload > 1 kohm
Frequency range: 0…800 Hz
Resolution: 11 bit + sign bit
Inaccuracy: 2% of full scale range
Connector pitch 3.5 mm, wire size 1.5 mm2
10 V ±1% and –10 V ±1%, Rload > 1 kohm
Connector pitch 3.5 mm, wire size 1.5 mm2
Physical layer: RS-485
Termination by jumper
Connector pitch 3.5 mm, wire size 1.5 mm2
For the drive to start, both connections (OUT1 to IN1, and OUT2 to IN2) must be closed
Connector: RJ-45
Cable length < 3 m
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 Planning the cabinet assembly.
Degrees of protection
IP20 (UL open type). See chapter Planning the cabinet assembly.
Technical data
78
Ambient conditions
Installation site altitude
Air temperature
Relative humidity
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
Environmental limits for the drive are given below. The drive is to be used in a heated,
indoor, controlled environment.
Operation
Storage
Transportation
installed for stationary use
in the protective package
in the protective package
0 to 4000 m (6600 ft) above sea level. [See also section
Altitude derating on page
72.]
-10 to +55°C (14 to 131°F). -40 to +70°C (-40 to +158°F) -40 to +70°C (-40 to +158°F)
No frost allowed. See section
Derating on page 72.
0 to 95%
Max. 95%
Max. 95%
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: According to IEC 60721-3-1: According to IEC 60721-3-2:
Chemical gases: Class 3C2
Solid particles: Class 3S2
Chemical cases: Class 1C2
Solid particles: Class 1S2
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.
–
Tested according to
IEC 60721-3-3, mechanical
conditions: Class 3M4
2…9 Hz: 3.0 mm (0.12”)
9…200 Hz: 10 m/s2 (33 ft/s2)
–
According to ISTA 1A.
Not allowed
Max. 100 m/s2 (330 ft/s2),
11 ms
76 cm (30”)
Chemical cases: Class 2C2
Solid particles: Class 2S2
–
According to ISTA 1A.
Max. 100 m/s2 (330 ft/s2),
11 ms
76 cm (30”)
Materials
Drive enclosure
Packaging
Disposal
• PC/ABS, colour NCS 1502-Y (RAL 9002 / PMS 420 C)
• hot-dip zinc coated steel sheet
• extruded aluminium AlSi.
Corrugated cardboard, PP bands.
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.
Technical data
79
Applicable standards
• EN 50178 (1997)
• IEC 60204-1 (2005),
modified
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 ACS850-04 into a cabinet.
Degrees of protection provided by enclosures (IP code)
• EN 60529: 1991
(IEC 60529)
• IEC 60664-1 (2007), Edition Insulation coordination for equipment within low-voltage systems. Part 1: Principles,
2.0
requirements and tests.
• IEC 61800-3 (2004)
Adjustable speed electrical power drive systems. Part 3: EMC requirements and specific
test methods.
• EN 61800-5-1 (2003)
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 ACS850-04 in a cabinet that is protected to IP3X for top surfaces for vertical access.
• prEN 61800-5-2
Adjustable speed electrical power drive systems.
Part 5-2: Safety requirements. Functional
• UL 508C (2002), Third
UL Standard for Safety, Power Conversion Equipment
Edition
• NEMA 250 (2003)
Enclosures for Electrical Equipment (1000 Volts Maximum)
• CSA C22.2 No. 14-05
Industrial Control Equipment
(2005)
Technical data
80
CE marking
A CE mark is attached to the drive to verify that the drive follows the provisions of the European Low
Voltage and EMC Directives (Directive 73/23/EEC, as amended by 93/68/EEC, and Directive 89/336/
EEC, as amended by 2004/108EC).
Compliance with the European Low Voltage 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 Planning the electrical installation 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.
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 (optional accessory).
2. The motor and control cables are selected as specified in the chapter Planning the electrical
installation.
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.
Technical data
81
WARNING! The drive may cause radio interference if used in a residential or domestic environment.
The user is required to take measures to prevent interference, in addition to the requirements for CE
compliance listed above, if necessary.
Compliance with EN 61800-3 (2004), category C3
The drive meets the requirements of the EMC Directive with the following provisions:
1. The drive is equipped with filtering option +E200.
2. The motor and control cables are selected as specified in the chapter Planning the electrical
installation.
3. The drive is installed according to the instructions given in this manual.
4. Motor cable length does not exceed 100 metres (328 ft).
Compliance with EN 61800-3 (2004), category C4
The drive meets the requirements of the EMC Directive with the following provisions:
1. It is ensured that no excessive emission is propagated to neighbouring low-voltage 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.
Medium voltage network
Supply transformer
Neighbouring network
Static screen
Point of measurement
Low voltage
Low voltage
Equipment
(victim)
Equipment
Drive
Equipment
2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available from
the local ABB representative.
3. The motor and control cables are selected as specified in the chapter Planning the electrical
installation.
4. The drive is installed according to the instructions given in this manual.
Compliance with the Machinery Directive
The drive is intended to be incorporated into machinery to constitute machinery covered by Machinery
Directive (98/37/EC) and does therefore not in every respect comply with the provisions of the directive.
For more information, see the Declaration of Incorporation by ABB Drives (code 64652770).
C-Tick marking
Pending.
Technical data
82
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 75.
Disconnecting device (Disconnecting means) – See section Supply disconnecting device on page
35.
Ambient conditions – The drive is to be used in a heated indoor controlled environment. See section
Ambient conditions on page 78 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 74.
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 74.
Power cable selection – See section Selecting the power cables on page 39.
Power cable connections – For the connection diagram and tightening torques, see section Power
cable connection on page 48.
Control connections – For the connection diagram and tightening torques, see section Connecting
the control cables on page 58.
Overload protection – The drive provides overload protection in accordance with the National
Electrical Code (US).
Braking – The ACS850-04 has an internal braking chopper. When applied with appropriately sized
braking resistors, the braking chopper will allow the drive to dissipate regenerative energy (normally
associated with quickly decelerating a motor). Braking resistor selection is discussed in the chapter
Resistor braking on page 91.
UL standards – See section Applicable standards on page 79.
Product protection in the US
This product is protected by one or more of the following US patents:
4,920,306
5,612,604
6,094,364
6,252,436
6,370,049
6,600,290
6,922,883
6,972,976
7,023,160
7,067,997
7,164,562
7,245,197
7,280,938
7,388,765
D512,026
D548,182S
5,301,085
5,654,624
6,147,887
6,265,724
6,396,236
6,741,059
6,940,253
6,977,449
7,034,510
7,082,374
7,176,779
7,250,739
7,330,095
D503,931
D512,696
D548,183S
Other patents pending.
Technical data
5,463,302
5,799,805
6,175,256
6,305,464
6,448,735
6,774,758
6,934,169
6,984,958
7,036,223
7,084,604
7,190,599
7,262,577
7,349,814
D510,319
D521,466
5,521,483
5,940,286
6,184,740
6,313,599
6,498,452
6,844,794
6,956,352
6,985,371
7,045,987
7,098,623
7,215,099
7,271,505
7,352,220
D510,320
D541,743S
5,532,568
5,942,874
6,195,274
6,316,896
6,552,510
6,856,502
6,958,923
6,992,908
7,057,908
7,102,325
7,221,152
7,274,573
7,365,622
D511,137
D541,744S
5,589,754
5,952,613
6,229,356
6,335,607
6,597,148
6,859,374
6,967,453
6,999,329
7,059,390
7,109,780
7,227,325
7,279,802
7,372,696
D511,150
D541,745S
83
Mains chokes
What this chapter contains
This chapter describes how to select and install mains chokes for the ACS850-04.
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 55).
Selection table
Mains chokes for ACS850-04
Drive type
Inductance
Type
ACS850-04xx…
µH
-03A0-4
-03A6-4
CHK-01
6370
-04A8-4
-06A0-4
CHK-02
4610
-08A0-4
-010A-4
CHK-03
2700
-014A-4
-018A-4
CHK-04
1475
-025A-4
-030A-4
-035A-4
-044A-4
(Internal choke as
standard)
-050A-4
-061A-4
-078A-4
-094A-4
581898
The mains chokes are protected to IP20. Refer to page 100 for dimensions, wire
sizes and tightening torques.
Mains chokes
84
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
AC supply
L1
U
L2
V
L3
W
DC supply
+
–
PE
PE
CHK-xx mains choke
X
Y
Z
JFI-xx EMC filter (if present)
ACS850-04
U1
V1
UDC+ UDC-
~
~
Mains chokes
W1
85
EMC filters
What this chapter contains
This chapter describes how to select and install EMC filters for the ACS850-04. 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 equipments 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.
EMC standards in general
EN 61800-3/A11 (2000), product
standard
1st environment,
unrestricted distribution
1st environment,
restricted distribution
2nd environment,
unrestricted distribution
2nd environment,
restricted distribution
EN 61800-3 (2004),
product standard
EN 55011, product family
standard for industrial,
scientific and medical (ISM)
equipment
Category C1
Group 1 Class B
Category C2
Group 1 Class A
Category C3
Group 2 Class A
Category C4
Not applicable
Filtering option +E200 is required in order to meet the category C3 level with the
ACS850-04 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. With
frame sizes A and B, option +E200 is an external filter of type JFI-A1 or JFI-B1; with
frame sizes C and D, the filter is internal.
An external EMC filter of the type JFI-0x is required in order to meet the category C2
level with the ACS850-04 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.
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).
EMC filters
86
Selection table
EMC filters for ACS850-04
Filter type
Drive type
EN 61800-3 (2004):
EN 61800-3 (2004):
ACS850-04xx…
Category C3
Category C2
-03A0-4
-03A6-4
Option code +E200
-04A8-4
JFI-02*
(external filter JFI-A1)
-06A0-4
-08A0-4
-010A-4
Option code +E200
-014A-4
JFI-03*
(external filter JFI-B1)
-018A-4
-025A-4
-030A-4
-035A-4
JFI-05*
-044A-4
Option code: +E200
(internal filter)
-050A-4
-061A-4
-078A-4
JFI-07*
-094A-4
*External filter; to be ordered separately
All EMC filters are protected to IP20. Refer to page 101 for dimensions of the JFI-x1
filters. Refer to page 103 for dimensions, wire sizes and tightening torques of the
JFI-0x filters.
EMC filters
87
JFI-A1/JFI-B1 (Frame A/B, category C3) installation
Installation guidelines
• 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.
Connection diagram
AC supply
L1
L2
L3
DC supply
+
PE
CHK-xx mains choke (if present)
–
JFI-x1 EMC filter
ACS850
U1
V1
W1
UDC+ UDC-
~
~
EMC filters
88
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
4
5
3
EMC filters
89
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
EMC filters
90
JFI-0x (Frames A…D, category C2) installation
Installation guidelines
• 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.
Connection diagram
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
ACS850
~
~
EMC filters
91
Resistor braking
What this chapter contains
This chapter describes how to select, protect and wire braking choppers and
resistors. The chapter also contains the technical data.
Braking choppers and resistors with the ACS850-04
Braking choppers
ACS850-04 (frame A…D) drives have a built-in braking chopper as standard
equipment to handle the energy generated by a decelerating motor.
When the braking chopper is enabled and a resistor connected, the chopper will start
conducting when the DC link voltage of the drive reaches 780 V. The maximum
braking power is achieved at 840 V.
Braking resistor selection
To select a braking resistor:
1. Calculate the maximum power generated by the motor during braking.
2. Calculate the continuous power based on the braking duty cycle.
3. Calculate the braking energy during the duty cycle.
Pre-selected resistors are available from ABB as shown in the table below. If the
listed resistor is not sufficient for the application, a custom resistor can be selected
within the limits imposed by the internal braking chopper of the ACS850-04. The
following rules apply:
• The resistance of the custom resistor must be at least Rmin. The braking power
capacity with different resistance values can be calculated from the following
formula
2
Pmax <
UDC
R
where UDC equals 840 V.
WARNING! Never use a braking resistor with a resistance below the value specified
for the particular drive type. The drive and the chopper are not able to handle the
overcurrent caused by the low resistance.
• The maximum braking power must not exceed Pbrmax at any point
• The average braking power must not exceed Pbrcont
Resistor braking
92
• The braking energy must not exceed the energy dissipation capacity of the
selected resistor
• It is highly recommended that the resistor be protected from thermal overload;
see the section Contactor protection of drive below.
Chopper data / Resistor selection table
The ratings apply at an ambient temperature of 40°C (104°F).
Drive type
ACS85004xx…
-03A0-4
-03A6-4
-04A8-4
-06A0-4
-08A0-4
Internal braking chopper
Rmin
Pbrcont Pbrmax
(kW)
(kW)
(ohm)
0.9
1.3
5.5
120
1.8
2.6
2.6
-010A-4
4.8
-014A-4
7.0
-018A-4
9.0
-025A-4
13.2
-030A-4
18.0
-035A-4
18.0
Example braking resistor
R
Type
(ohm)
Pn
(W)
Epulse
(kJ)
JBR-01
(Danotherm CAR 155 D T 414 120R)
120
105
22
7.9
80
JBR-03
(Danotherm CAR 200 D T 415 80R)
80
135
40
14.6
40
JBR-04
(Danotherm CBR-V 210 D T 415 40R)
40
360
73
30.7
20
JBR-05
(Danotherm CBR-V 330 D T 415 20R)
20
570
77
43.9
13
JBR-06
(Danotherm CBR-V 460 D HT 415 13R)
13
790
132
-044A-4
-050A-4
-061A-4
26.4
-078A-4
-094A-4
581898
Pbrcont The internal chopper will withstand this continuous braking power. The braking is considered
continuous if the braking time exceeds 30 seconds.
Pbrmax Maximum braking power of the chopper. The chopper will withstand this braking power for 1
second within every 10 seconds. Note: The listed resistors will withstand this braking power
for 1 second within every 120 seconds.
The minimum allowed resistance of the braking resistor.
Rmin
R
Resistance of the listed resistor.
Pn
Continuous power (heat) dissipation of the listed resistor when cooled naturally in a vertical
position.
Epulse Energy pulse the listed resistor will withstand.
The braking resistors are protected to IP20. Refer to page 105 for dimensions, wire
sizes and tightening torques for the resistors.
Resistor braking
93
Resistor installation and wiring
All resistors must be installed outside the drive module in a place where they are
cooled sufficiently, do not block the airflow to other equipment, or dissipate hot air
into the air inlets of other equipment.
WARNING! The materials near the braking resistor must be non-flammable. The
surface temperature of the resistor may rise above 200 °C (400 °F), and the
temperature of the air flowing from the resistor is hundreds of degrees Celsius.
Protect the resistor against contact.
The maximum length of the resistor cable(s) is 20 m (65 ft). For the connections, see
section Power cable connection on page 48.
Contactor protection of drive
It is highly recommended to equip the drive with a main contactor for safety reasons.
Wire the contactor so that it opens in case the resistor overheats. This is essential
for safety since the drive will not otherwise be able to interrupt the main supply if the
chopper remains conductive in a fault situation.
Below is a simple example wiring diagram.
L1 L2 L3
1
OFF
Fuses
2
1
3
5
13
3
ON
2
4
6
14
4
ACS850
U1 V1 W1
Θ
Resistor thermal switch
K1
Resistor braking
94
Braking circuit commissioning
For more information, see the appropriate Firmware Manual.
• Enable the braking chopper function. Please note that a braking resistor must be
connected when the chopper is enabled
• Switch off the overvoltage control of the drive
• Adjust any other relevant parameters in group 48.
WARNING! If the drive is equipped with a braking chopper but the chopper is not
enabled by parameter setting, the braking resistor must be disconnected because
the protection against resistor overheating is then not in use.
Resistor braking
95
Dimension drawings
What this chapter contains
Dimension drawings of the ACS850-04 and related accessories are shown below.
The dimensions are given in millimetres and [inches].
Dimension drawings
96
Frame size A
Dimension drawings
97
Frame size B
Dimension drawings
98
Frame size C
Dimension drawings
99
Frame size D
Dimension drawings
100
Mains chokes (type CHK-0x)
68906903
CHK-xx dimensions
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
mm2 (AWG)
Tightening torque – Main terminals
N·m (lbf·in)
PE/Chassis terminals
Tightening torque – PE/Chassis terminals
N·m (lbf·in)
Dimension drawings
CHK-01
120 (4.72)
146 (5.75)
79 (3.11)
77 (3.03)
114 (4.49)
M5
1.8 (4.0)
0.5 … 10
(20…6)
Choke type
CHK-02 CHK-03
150 (5.91) 150 (5.91)
175 (6.89) 175 (6.89)
86 (3.39) 100 (3.94)
105 (4.13) 105 (4.13)
148 (5.83) 148 (5.83)
M5
M5
3.8 (8.4) 5.4 (11.9)
0.5 … 10 0.5 … 10
(20…6)
(20…6)
CHK-04
150 (5.91)
175 (6.89)
100 (3.94)
105 (4.13)
148 (5.83)
M5
5.2 (11.5)
0.5 … 10
(20…6)
1.5 (13)
1.5 (13)
1.5 (13)
1.5 (13)
M4
M5
M5
M5
3 (26)
4 (35)
4 (35)
4 (35)
101
EMC filters (type JFI-x1)
JFI-A1
Dimension drawings
102
JFI-B1
Dimension drawings
103
EMC filters (type JFI-0x)
Dimension drawings
Dimension drawings
Dim. A mm (in.)
Dim. B mm (in.)
Dim. C mm (in.)
Dim. D mm (in.)
Dim. E mm (in.)
Dim. F mm (in.)
Dim. G mm (in.)
Dim. H mm (in.)
Dim. I mm (in.)
Dim. J
Dim. K mm (in.)
Dim. L mm (in.)
Weight kg (lbs)
Wire size (solid)
mm2 (AWG)
Wire size (stranded)
mm2 (AWG)
Tightening torque of
terminals N·m (lbf·in)
Parameter
JFI-xx dimensions
Filter type
JFI-02
JFI-03
JFI-05
250 (9.84)
250 (9.84)
250 (9.84)
45 (1.77)
50 (1.97)
85 (3.35)
70 (2.76)
85 (3.35)
90 (3.54)
220 (8.66)
240 (9.45)
220 (8.66)
235 (9.25)
255 (10.04)
235 (9.25)
25 (0.98)
30 (1.18)
60 (2.36)
5.4 (0.21)
5.4 (0.21)
5.4 (0.21)
1 (0.04)
1 (0.04)
1 (0.04)
22 (0.87)
25 (0.98)
39 (1.54)
M5
M5
M6
22.5 (0.89)
25 (0.98)
42.5 (1.67)
29.5 (1.16)
39.5 (1.56)
26.5 (1.04)
0.8 (1.75)
1.1 (2.4)
1.8 (4.0)
0.2 … 10
0.5 … 16
6…35
(AWG24…8)
(AWG20…6) (AWG8…2)
0.2 … 6
0.5 … 10
10…25
(AWG24…10) (AWG20…8) (AWG6…4)
1.5 … 1.8
1.5 … 1.8
4.0 … 4.5
(13.3 … 15.9) (13.3 … 15.9)
(35 … 40)
JFI-07
270 (10.63)
90 (3.54)
150 (5.91)
240 (9.45)
255 (10.04)
65 (2.56)
6.5 (0.26)
1.5 (0.06)
45 (1.77)
M10
45 (1.77)
64 (2.52)
3.9 (8.5)
16…50
(AWG4…1/0)
16…50
(AWG4…1/0)
7…8
(60…70)
104
105
Braking resistors (type JBR-xx)
Dimension drawings
Dimension drawings
Dim. A mm (in.)
Dim. B mm (in.)
Dim. C mm (in.)
Dim. D mm (in.)
Dim. E mm (in.)
Dim. F mm (in.)
Weight kg (lbs)
Max. wire size –
Main terminals
Tightening torque –
Main terminals
Max. wire size – Thermal
switch terminals
Tightening torque –
Thermal switch terminals
Parameter
0.6 … 0.8 N·m (5.3 … 7.1 lbf·in)
4 mm2 (AWG12)
1.5 … 1.8 N·m (13 … 16 lbf·in)
10 mm2 (AWG6)
JBR-xx dimensions
Resistor type
JBR-01
JBR-03
JBR-04
JBR-05
JBR-06
295 (11.61) 340 (13.39)
–
–
–
155 (6.10)
200 (7.87)
–
–
–
125 (4.92)
170 (6.69)
–
–
–
–
–
345 (13.58) 465 (18.31) 595 (23.43)
–
–
210 (8.27) 330 (12.99) 460 (18.11)
–
–
110 (4.33) 230 (9.06) 360 (14.17)
0.75 (1.7)
0.8 (1.8)
1.8 (4.0)
3.0 (6.6)
3.9 (8.6)
106
3AUA0000045496 REV A EN
EFFECTIVE: 3.11.2008
ABB Oy
AC Drives
P.O. Box 184
FI-00381 HELSINKI
FINLAND
Telephone
+358 10 22 11
Fax
+358 10 22 22681
Internet
http://www.abb.com
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