ABB ACS850 series, ACS850-04 series Hardware Manual

ACS850

Hardware Manual

ACS850-04 Drive Modules (200 to 500 kW, 250 to 600 hp)

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]

List of related manuals

Manual

STANDARD MANUALS

ACS850-04 Hardware Manual 200 to 500 kW (250 to 600 hp)

ACS850 Standard Control Program Firmware Manual

ACS850 Quick Start-up Guide (Standard Control Program)

ACS850 Control Panel User's Guide

OPTION MANUALS

ACS-CP-U Control Panel IP54 Mounting Platform Kit (+J410)

Installation Guide

Fieldbus Adapters, I/O Extension Modules etc.

Code (EN)

3AUA0000026234

3AUA0000045497

3AUA0000045498

3AUA0000050277

3AUA0000049072


ACS850-04 Drive Modules

200 to 500 kW (250 to 600 hp)

Hardware Manual

3AUA0000026234 Rev B EN

EFFECTIVE: 26.6.2009

© 2009 ABB Oy. All Rights Reserved.



Table of contents

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

Table of contents

Safety instructions

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Use of warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Safety in installation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Electrical safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Fiber optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Safe start-up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Introduction to the manual


Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Categorization by option code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Quick installation, commissioning and operating flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Operation principle and hardware description


What the ACS850-04 is . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Alternative output busbar configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Control unit variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Component placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Power connections and control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Cables for connecting the control unit to the drive module and control panel . . . . . . . . . . . . 31

Circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5

Table of contents


6

Planning the cabinet installation

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Basic requirements for the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Planning the layout of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Layout examples, door closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Layout examples, door open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Arranging the grounding inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Selecting busbar material and preparation of the joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Planning the fastening of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Planning the cabinet placement on a cable channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Planning the Electro Magnetic Compatibility (EMC) of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . .39

Planning the grounding of the cable shields at the cabinet lead-through . . . . . . . . . . . . . . . . . . . . .41

Planning the cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Preventing the recirculation of hot air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Prevention the air recirculation outside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Prevention the air recirculation inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Required free space around the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Free space at top with high air inlet gratings in the cabinet door . . . . . . . . . . . . . . . . . . . . . .44

Free space at top with low air inlet gratings in the cabinet door . . . . . . . . . . . . . . . . . . . . . . .44

Free space at the side and front of the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Other installation positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Planning the placement of the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Planning the use of the cubicle heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Mechanical installation


Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Checking the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Moving and unpacking the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Checking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Attaching the warning stickers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Fastening the cable lug terminals to the output busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Fastening the drive module to the cabinet base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Installing the drive control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Mounting through the fastening holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Vertical DIN rail mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Horizontal DIN rail mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Planning the electrical installation


Selecting the supply disconnecting device (disconnecting means) . . . . . . . . . . . . . . . . . . . . . . . . .57

European Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Other regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Selecting and dimensioning the main contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Table of contents


7

Checking the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Typical power cable sizes (US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Signals in separate cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Signals allowed to be run in the same cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Relay cable type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Control panel cable length and type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Continuous motor cable shield or enlosure for equipment in the motor cable . . . . . . . . . . . . 69

Implementing thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Protecting the drive and input power cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Protecting the motor and motor cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Protecting the drive and the input power and motor cables against thermal overload . . . . . 70

Protecting the motor against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Protecting the drive against ground faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Residual current device compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Implementing the Emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Implementing the Safe Torque Off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Implementing the Power-loss ride-through function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Using power factor compensation capacitors with the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Implementing a safety switch between the drive and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Using a contactor between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Implementing a bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Connecting a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Example circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Electrical installation


Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Input cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Brake resistor and resistor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Table of contents


8

Checking the combatibility with IT (ungrounded) and TN (corner grounded) systems . . . . . . . . . . .78

Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

Input cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

Removing the protective covering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

Motor cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

Checking the settings of the cooling fan transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

Removing the cover assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

Fastening the control cable clamp plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

Grounding the control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

Connecting the control unit to the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

Default I/O connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

External power supply for the JCU Control Unit (XPOW) . . . . . . . . . . . . . . . . . . . . . . .89

DI6 (XDI:6) as a thermistor input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Drive-to-drive link (XD2D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90

Safe torque off (XSTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Control cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Routing the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Installing optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Wiring the modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Installation checklist


Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

Cabinet construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

Instrumentation, busbars and cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

Groundings and protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

Labels, switches, fuses and doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

Cooling and driven equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

Start-up


Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

Fault tracing

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

Warning and fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

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9

Maintenance

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Replacing the cooling fan of the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Replacing the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Replacing the capacitor pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Technical data

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Ambient temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Fuses (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Calculation example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Fuse tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 gG fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Ultrarapid (aR) fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Quick guide for selecting between gG and aR fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Fuses (UL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

UL class T and L fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Dimensions, weights and free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Losses, cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

IP22 cabinet with no extra fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

IP54 cabinet with an extra fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Terminal and lead-through data for the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Terminal data for the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Electrical power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Motor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Brake resistor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Control unit (JCU-11) connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

“C-tick” marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

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10

Compliance with the EN 61800-3:2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124

Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

Category C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126

UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126

CSA marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126

Patent protection in the USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126

Dimension drawings


Frame size G without pedestal (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127

Frame size G with busbars on the left side (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128

Frame size G pedestal busbars on the long side (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129

Drive control unit (JCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130

Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131

Dimension drawings (USA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132

Frame size G without pedestal (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132

Frame size G with busbars on the left side (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133

Frame size G pedestal busbars on the long side (inches) . . . . . . . . . . . . . . . . . . . . . . . . . .134

Example circuit diagrams

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135

Example circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136

Resistor braking


Availability of brake choppers and resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137

When is resistor braking needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137

Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137

Hardware description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137

Planning the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137

Selecting the brake circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137

Placing the brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

Protecting the system in fault situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139

Thermal overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139

Short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139

Selecting and routing the brake circuit cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139

Minimizing electromagnetic interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140

Cable length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140

EMC compliance of the complete installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140

Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140

Brake circuit commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140

Table of contents


11

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Combined braking cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Brake resistor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

SAFUR resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Maximum resistor cable length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Du/dt filters and sine filters

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 du/dt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

When is du/dt filter needed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Description, installation and technical data of the FOCH filters . . . . . . . . . . . . . . . . . . . . . . 143

Sine filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Further information

Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Table of contents


12

Table of contents


13

Safety instructions

What this chapter contains

This chapter contains the safety instructions which you must follow when installing, operating and servicing the drive. If ignored, physical injury or death may follow, or damage may occur to the drive, motor or driven equipment. Read the safety instructions before you work on the unit.

Use of warnings

Warnings caution you about conditions which can result in serious injury or death and/or damage to the equipment and advise on how to avoid the danger. The following warning symbols are used in this manual:

Electricity warning warns of hazards from electricity 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 sensitive devices 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


14

Safety in installation and maintenance

Electrical safety

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

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

•

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

•

Never work on the drive, motor cable or motor when main power is applied.

After disconnecting the input power, always wait for 5 min to let the intermediate circuit capacitors discharge before you start working on the drive, motor or motor cable.

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

1. voltage between drive input phases U1, V1 and W1 and the frame is close to

0 V.

2. voltage between terminals UDC+ and UDC- and the frame is close to 0 V.

•

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 cause dangerous voltages inside the drive even when the main power on the drive is switched off.

•

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

•

When reconnecting the motor cable, always check that the phase order is correct.

Note:

•

The motor cable terminals on the drive are at a dangerously high voltage when the input power is on, regardless of whether the motor is running or not.

•

The brake control terminals (UDC+, UDC-, R+ and R- terminals) carry a dangerous DC voltage (over 500 V).

•

Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V) may be present on the terminals of relay outputs (X2) or Safe Torque Off (X6).

•

The Safe Torque Off function does not remove the voltage from the main and auxiliary circuits.



15

Grounding

These instructions are intended for all who are responsible for the grounding of the drive.

WARNING!

Ignoring the following instructions can cause physical injury, death, increased electromagnetic interference and equipment malfunction:

•

Ground the drive, motor and adjoining equipment to ensure personnel safety in all circumstances, and to reduce electromagnetic emission and interference.

•

Make sure that grounding conductors are adequately sized as required by safety regulations.

•

In a multiple-drive installation, connect each drive separately to protective earth (PE).

•

Where EMC emissions must be minimized, make a 360° high frequency grounding of cable entries at the cabinet lead-through in order to suppress electromagnetic disturbances. In addition, connect the cable shields to protective earth (PE) in order to meet safety regulations.

Note:

•

Power cable shields are suitable for equipment grounding conductors only when adequately sized to meet safety regulations.

•

As the normal leakage current of the drive is higher than 3.5 mA AC or 10 mA

DC, a fixed protective earth connection is required by EN 50178, 5.2.11.1.



16

Permanent magnet motor drives

These are additional warnings concerning permanent magnet motor drives. Ignoring the instructions can cause physical injury or death, or damage to the equipment.

WARNING!

Do not work on the drive when the permanent magnet motor is rotating.

Also, when the supply power is switched off and the inverter is stopped, a rotating permanent magnet motor feeds power to the intermediate circuit of the drive and the supply connections become live.

Before installation and maintenance work on the drive:

• Stop the motor.

• Ensure that there is no voltage on the drive power terminals according to step 1 or

2, or if possible, according to the both steps.

1. Disconnect the motor from the drive with a safety switch or by other means.

Measure that there is no voltage present on the drive input or output terminals

(U1, V1, W1, U2, V2, W2, UDC+, UDC-).

2. Ensure that the motor cannot rotate during work. Make sure that no other system, like hydraulic crawling drives, is able to rotate the motor directly or through any mechanical connection like felt, nip, rope, etc. Measure that there is no voltage present on the drive input or output terminals (U1, V1, W1, U2, V2, W2, UDC+,

UDC-). Ground the drive output terminals temporarily by connecting them together as well as to the PE.



17

General safety

These instructions are intended for all who install and service the drive.

WARNING!

Ignoring the following instructions can cause physical injury or death, or damage to the equipment:

•

Handle the unit carefully.

•

The drive module is heavy 200 kg (441 lb).

Lift it by the upper part only using the lifting lugs attached to the top of the unit. The lower part will be deformed from lifting. Do not remove the pedestal before lifting.

Do not tilt the drive.

The centre of gravity of the unit is high.

The unit will overturn from a tilt of about 6 degrees. An overturning unit can cause physical injury.

M ax

3

0°

Do not lift by the lower part of the frame.

Do not tilt!

•

Beware of hot surfaces. Some parts, such as heatsinks of power semiconductors, remain hot for a while after disconnection of the electrical supply.

•

Make sure that dust from borings and grindings does not enter the drive when installing. Electrically conductive dust inside the unit may cause damage or malfunctioning.

•

Ensure sufficient cooling.

•

Do not fasten the drive by riveting or welding.



18

Fiber optic cables

WARNING!

Ignoring the following instructions can cause equipment malfunction and damage to the fiber optic cables:

•

Handle the fiber optic cables with care. When unplugging optic cables, always grab the connector, not the cable itself. Do not touch the ends of the fibers with bare hands as the fiber is extremely sensitive to dirt. The minimum allowed bend radius is 35 mm (1.4 in.).

Printed circuit boards

WARNING!

Ignoring the following instructions can cause damage to the printed circuit boards:

•

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



19

Safe start-up and operation

General safety

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

WARNING!

Ignoring the following instructions can cause physical injury or death, or damage to the equipment:

•

Before adjusting the drive and putting it into service, make 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 any automatic fault reset functions of the drive control program 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 keys and , or commands via the I/O board of the drive. The maximum allowed number of charging cycles of the DC capacitors ie, power-ups by applying power, is five in ten minutes.

Note:

•

If an external source for start command is selected and it is ON, the drive will start immediately after an input voltage break or fault reset unless the drive is configured for 3-wire (a pulse) start/stop.

•

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

Permanent magnet motor drives

WARNING! Do not run the motor over the rated speed. Motor overspeed leads to overvoltage which may damage or explode the capacitors in the intermediate circuit of the drive.



20



21

Introduction to the manual


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

Target audience

This manual is intended for panel builders and system integrators who

• plan the cabinet assembly of the drive module and install the module into a userdefined cabinet

• plan the electrical installation of a drive cabinet

• make instructions for the end user of the drive conserning the mechanical installation of the drive cabinet, power and control cabling and maintenance.

Read the manual before working on the drive. You are expected to know the fundamentals of electricity, wiring, electrical components and electrical schematic symbols.

The manual is written for readers worldwide. Both SI and imperial units are shown.

Special US instructions for installations within the United States that must be installed per the National Electrical Code and local codes are marked with (US).

Contents of the manual

This manual contains the instructions and information for the basic drive module configuration. The chapters of the manual are briefly described below.

Safety instructions give safety instructions for the installation, commissioning, operation and maintenance of the drive module.

Introduction to the manual introduces the manual.

Operation principle and hardware description describes the drive module.

Planning the cabinet installation guides in planning drive cabinets and installing the drive module into a user-defined cabinet. The chapter gives cabinet layout examples and free space requirements around the module for cooling.

Mechanical installation describes how to install the basic drive module into a cabinet.

Introduction to the manual


22

Planning the electrical installation instructs in the motor and cable selection, protections and cable routing.

Electrical installation instructs in how to wire the drive.

Installation checklist contains lists for checking the mechanical and electrical installation of the drive.

Start-up describes the start-up procedure of the drive.

Fault tracing describes the fault tracing of the drive.

Maintenance contains preventive maintenance instructions.

Technical data contains the technical specifications of the drive module eg, the ratings, sizes and technical requirements, provisions for fulfilling the requirements for

CE and other markings.

Dimension drawings contains dimension drawings of the drive modules and auxiliary components.

Example circuit diagram shows an example circuit diagram for a cabinet-installed drive module.

Resistor braking to select, protect and wire brake resistors.

Du/dt filters and sine filters describes how to select du/dt filters for the drive.

Categorization by option code

The instructions and technical data which concern only certain optional selections are marked with option codes eg, +E210. The options included in the drive can be identified from the option codes visible on the type designation label. The option selections are listed in section Type designation key on page 32 .

Quick installation, commissioning and operating flowchart

Task See

Plan the electrical installation.

Check the ambient conditions, ratings, required cooling air flow, input power connection, compatibility of the motor, motor connection, and other technical data.

Select the cables.

Planning the cabinet installation (page 35 )

Planning the electrical installation (page 57 )

Technical data (page 111 )

Resistor braking (page 137 )

Option manual (if optional equipment is included)



23

Task

Unpack and check the units.

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

Only intact units may be started up.

See

Mechanical installation (page 48 )

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

Technical data: Ambient conditions (page 122 ) Check the installation site.

Fasten the base of the cabinet to floor. Install the drive module into the cabinet.

Mechanical installation (page 47 )

Route the cables.

Planning the electrical installation: Routing the cables (page 67 )

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 77 )

Connect the power cables.

Connect the control and the auxiliary control cables.

Connecting the power cables (page 79 ),

Connecting the control unit to the drive module

(page 85 ), Connecting the control cables (page

86 ), Resistor braking: Electrical installation

(+D150 units, page 140)

Manuals for any optional equipment

Check the installation.

Installation checklist (page 95 )

Commission the drive.

Commission the brake chopper (if used).

Start-up (page 99

Resistor braking

)

(page 140 )

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

Appropriate Firmware Manual



24

Terms and abbreviations

Term/Abbreviation

EMC

EMI

FIO-01

FIO-11

FIO-21

FEN-01

FEN-11

FEN-21

FCAN-0x

FDNA-0x

FENA-0x

FLON-0x

FSCA-0x

FPBA-0x

Frame (size)

FSCA-0x

IGBT

I/O

JCU

JINT

JMU-xx

RFI

HTL

TTL

Explanation

Electromagnetic Compatibility

Electromagnetic Interference

Optional digital I/O extension

Optional analogue I/O extension

Optional analog and digital I/O extension

Optional TTL encoder interface

Optional absolute encoder interface

Optional resolver interface

Optional CANopen adapter

Optional DeviceNet adapter

Optional Ethernet/IP adapter

Optional LonWorks adapter

Optional Modbus adapter

Optional PROFIBUS DP adapter

Size of the drive module. The drive modules described in this manual are of frame size G.

Optional Modbus adapter

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

Input/Output

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

Main circuit board

The memory unit attached to the control unit of the drive

Radio-frequency interference

High-threshold logic

Transistor-transistor logic



25

Operation principle and hardware description


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

What the ACS850-04 is

The ACS850-04 is a drive module for controlling asynchronous AC induction motors and permanent magnet synchronous motors.

The main circuit of the drive module is shown below.

AC supply

U1

V1

W1

ACS850-04

Capacitor bank

Rectifier Inverter

U2

V2

W2

Motor output

Brake chopper

(optional

R- UDC+ UDC-

R+

This table describes the operation of the main circuit in short.

Component

Rectifier

Capacitor bank

Inverter

Brake chopper

Description

Converts the three-phase AC voltage to DC voltage.

Energy storage which stabilizes the intermediate circuit DC voltage.

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

Connects the external brake resistor to the intermediate DC circuit when the voltage in the circuit exceeds its maximum limit.

Operation principle and hardware description


26

Product overview

The degree of protection of the drive module is IP00. The module must be installed into a cabinet by the customer.

Layout

The components of the standard unit are shown below.

Fastening points

Lifting lug

Drive module Cables going to the JCU Control Unit and

APOW board are coiled on the top of the module.

Input cable terminals

Fastening points

Fastening points

Front cover

Motor cable terminals

Additional holes for fastening the cable terminals

PE terminal

Alternative output cable terminals (when no vertical busbars are used)

Busbars for connecting optional vertical brake and DC busbars

Pedestal

Fastening bracket

Control unit

(JCU)

Control cable clamp plate



27

The control unit layout is shown below (cover assembly and protective coverings of the slots removed).

Slots 1 and 2 for optional I/O extensions and encoder/resolver interface

Slot 3 for optional fieldbus adapter

External 24 V power input

Relay outputs

+24VD

Digital inputs

Digital input/outputs

Analog inputs

Analog outputs

Drive-to-drive link

Safe Torque Off connection

Control panel / PC connection

Memory unit (JMU) connection



28

Alternative output busbar configurations

The motor and brake busbars can be fastened on the left-hand long side of the module and DC busbars on the right-hand side. Alternatively, the motor and brake busbars can be fastened on the right-hand long side of the module and DC busbars on the left-hand side. The output busbars can also be fastened on the short back side of the module. For more information, contact your local ABB representative.

Output busbars on the short side of the module

Control unit variants a)

1 a)

Control unit with front cover a) When covers are removed

Control unit with control panel holder (+J414) a) When cover (1) is removed.

Control unit with control panel (+J400)



Component placement

The component layout stickers of the drive module are shown below. The stickers show all possible components. Not all of them are present in each delivery or described here. Components that need to be changed regularly are listed below:

Designation Component

Y41 Cooling fan

C201-C214 Capacitors

29

64601423



30

Power connections and control interfaces

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

Slot 1 / Slot 2

FIO-01 (Digital I/O extension)

FIO-11 (Analog I/O extension)

FIO-21 (Analog and digital

I/O extension) )

FEN-01 (TTL incremental encoder interface)

FEN-11 (TTL absolute encoder interface)

FEN-21 (Resolver interface)

FEN-31 (HTL incremental encoder interface)

Note: No two resolver/ encoder 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)

FSCA-01 (Modbus)

FPBA-0x (PROFIBUS)

FXX

FXX

FXXX

Slot 1

Slot 2

Slot 3

Control unit (JCU)

X7

Control panel or PC

Memory unit

1) 1)

See page 110.

External power input

*Relay outputs (3 pcs)

24 V DC output

*Digital inputs (6 pcs)

*Digital input/outputs (2 pcs)

*Analog inputs

*Analog outputs

Drive-to-drive link

Safe Torque Off

XPOW

XRO1…3

XD24

XDI

XDIO

XAI

XAO

XD2D

XSTO

For intormation on default connections, see page 87.

For specifications, see page 119 .

* programmable.

3-phase power supply

PE

L1

L2

L3

PE

U1

V1

W1

Brake resistor (optional)

Power unit

Brake chopper

R-

UDC+

R+ UDC-

U2

V2

W2 2)

M

3 ~

AC motor

2)

du/dt or sine filter (optional, see page 143 ) t°



Cables for connecting the control unit to the drive module and control panel

The cables connectiong the drive module and control panel to the control unit are shown below. See pages 86 and 87 for the actual connections.

31

JCU Control Unit

ø 4.5 (0.18”)

80 (3.15”)

Shield

Drive module

APOW

JRIB 300 mm (12 in.)

2100 mm (83 in.)

Protective tube

JINT

3 m (118 in.)

Category 5e cable

3 m ( 118 in.)

Circuit boards

The drive contains the following printed circuit boards as standard:

• main circuit board (JINT)

• control and I/O board (JCON) inside the JCU Control Unit

• adapter board (JRIB) connected to the JCON board

• input bridge control board (AINP)

• input bridge protection board (AIBP) which includes snubbers for the thyristors and varistors

• power supply board (APOW)

• gate driver control board (AGDR)

• diagnostics and panel interface board (JDPI)

• brake chopper control board (ABRC) with option +D150



32

Type designation label

The type designation label includes an IEC and NEMA rating, CE, C-UL US, and

CSA markings, a type designation and a serial number, which allow individual recognition of each unit. The first digit of the serial number refers to the manufacturing plant. The next four digits refer to the unit’s manufacturing year and week respectively. The remaining digits complete the serial number so that there are no two units with the same serial number. The type designation label is located on the front cover. An example label is shown below.

Type designation, see section Type designation key on page 32.

Ratings Serial number

Frame size

Type designation key

The type designation contains information on the specifications and configuration of the drive module. The first digits from left express the basic configuration eg,

ACS850-04-430A-5. The optional selections are given thereafter, separated by plus signs eg, +E210. The main selections are described below. Not all selections are available for all types. For more information, refer to ACS850-04 Ordering

Information (3AUA0000027760), available on request.

Selection Alternatives

Product series

Type

+ options

Resistor braking

ACS850 product series

04 Drive module. When no options are selected: IP00 (UL open type), top entry, side exit,

JCU Drive Control Unit with front cover but no control panel, no EMC filter, Standard

Control Program, Safe Torgue Off function, coated boards, pedestal with output on the long side, output busbar set for motor, pedestal busbars for brake resistor and DC connection, base and wall mounting brackets, Hardware manual and Quick Start-up

Guide (multilingual) and CD containing all manuals.

Size Refer 111

Voltage range (nominal rating in bold)

5 380/400/415/440/460/480/ 500 VAC

D150 Brake chopper

Filter E210 EMC/RFI filter for second environment TN/IT (grounded/ungrounded) system, category 3

E208 common mode filter



33

Selection

Control panel and control unit

Fieldbus

I/O extensions and feedback interfaces

Programs and functions in memory unit

Warranty

Paper manuals

Alternatives

J400 Control panel inserted onto the JCU Control Unit. Includes control panel mounting platform and internal cable.

J410 Control panel with door mounting kit. Includes control panel mounting platform, IP54 cover and a 3-meter panel connection cable.

J414 Control panel holder with cover and internal cable but no control panel. Not to be used with +J400.

0C168 Without front cover for the JCU Control Unit

K...

L...

N...

+K451: FDNA-01 DeviceNet adapter

+K452: FLON-01 LonWorks adapter

+K454: FPBA-01 PROFIBUS DP adapter

+K457: FCAN-01 CANopen adapter

+K458: FSCA-01 Modbus adapter

+K466: FENA-01 Ethernet/IP and Modbus/TCP adapter

+L500: FIO-11 analogue I/O extension

+L501: FIO-01 digital I/O extension

+L502: FEN-31 HTL incremental encoder interface

+L516: FEN-21 resolver interface

+L517: FEN-01 TTL incremental encoder interface

+L518: FEN-11 TTL absolute encoder interface

+L519: FIO-21 analogue and digital I/O extension

+N697 Crane control program

P904 Extended warranty

R… +R700: English

+R701: German

+R702: Italian

+R703: Dutch

+R704: Danish

+R705: Swedish

+R706: Finnish

+R707: French

+R708: Spanish

+R709: Portuguese

+R711: Russian

+R712: Chinese

+R714: Turkish

Note: The delivered manual set may include manuals in English if the translation is not available.



34



35

Planning the cabinet installation


This chapter guides in planning drive cabinets and installing the drive module into a user-defined cabinet so that the front of the module faces the cabinet door. The chapter gives cabinet layout examples and free space requirements around the module for cooling. The issues discussed are essential for the safe and trouble-free use of the drive system.

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.

Basic requirements for the cabinet

Use a cabinet which:

• has a frame sturdy enough to carry the weight of the drive components, control circuitry and other equipment installed in it. If the cabinet is allowed to be placed on a cable channel, ensure that the cabinet structure carries the weight also in this way of installation.

• protects the user and drive module against contact and meets the requirements for dust and humidity.

Planning the cabinet installation


36

Planning the layout of the cabinet

Design a spacious layout to ensure easy installation and maintenance. Sufficient cooling air flow, obligatory clearances, cables and cable support structures all require space.

Place the control board(s) away from:

• the main circuit components such as contactor, switches and power cables

• hot parts (heat sink, air outlet of the drive module).

Layout examples, door closed

Layout examples for IP22 and IP54 cabinets are shown below.

IP22 IP54

2c

2b 2a

3

4

5

1a

3

4

5

1a

1a Air inlet for the drive module

1b Air inlet for the other equipment

2a Air outlet for the drive module

2b Air outlet for the other equipment

2c Air outlet for the drive module and the other equipment, an extra exhaust fan

3 Drive control panel (Control Panel Door

Mounting kit, +J410). The control panel is connected to the JCU Control Unit inside the cabinet)

4 Contactor control switch and emergency stop switch (connected to the contactor control circuit inside the cabinet)

5 Operating handle of the disconnector

1a 1a

1b 1b

Roof air flow viewed from top



Layout examples, door open

Layout examples for IP22 and IP54 cabinets are shown below

IP22 IP54

1

5 n

8

3

4

9 n

3

6

2

3

3 7

PE

1

5 n

8

3

4

9 n

3

2

6

3

1 Supporting frame of the cabinet

2 Air baffles that separate the cool and hot areas (leak-proof lead-throughs)

3 Input power cable including the protective conductors to cabinet grounding (PE)

4 Disconnector and fuses

5 Contactor

6 Drive module

7 Motor cable including the grounding conductors

8 JCU Control Unit

9 External control cables

10 Fan

3 7

PE

37

IP22 IP54

10

2 2

Air flow to the roof Air flow through the drive module

Note: See also section Required free space around the drive module , page 43 .

WARNING!

Never use the module without the pedestal.



38

Arranging the grounding inside the cabinet

Arrange proper grounding for any cross-members or shelves on which components are mounted:

• Leaving the component connecting surfaces unpainted will form a proper grounding contact to cabinet frame.

• The drive module will be grounded to the cabinet frame via its fastening screws.

Selecting busbar material and preparation of the joints

If planning the use of busbars, note the following:

• Tin-plated copper is recommended. Aluminium can also be used.

• For the joints of aluminium busbars, the oxide layer must be removed and suitable anti-oxidant joint compound applied.

Tightening torques

Apply the following torques to grade 8.8 screws (with or without joint compound) that tighten electric contacts.

Screw size

M5

M6

M8

M10

M12

M16

Torque

3.5 N·m (2.6 lbf·ft)

9 N·m (6.6 lbf·ft)

20 N·m (14.8 lbf·ft)

40 N·m (29.5 lbf·ft)

70 N·m (52 lbf·ft)

180 N·m (133 lbf·ft)

Planning the fastening of the cabinet

Note the following when planning the fastening of the cabinet:

• The cabinet must be fastened to the floor from front and back.

• If fastening at the back is not possible or the cabinet will be exposed to vibration, the cabinet must be fastened at the top to the rear wall/roof.

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



39

Planning the cabinet placement on a cable channel

Note the following when planning to place the cabinet on a cable channel:

• The cabinet structure must be sturdy enough. If the whole cabinet base will not be supported from below, the cabinet weight will lie on the sections that the floor carries.

• The cabinet must have a sealed bottom plate and cable lead-throughs to ensure the degree of protection and to prevent the cooling air flow from the cable channel into the cabinet.

Cable channel

Cables

The carrying structure on a cable channel Cabinet side view with a bottom plate

Planning the Electro Magnetic Compatibility (EMC) of the cabinet

Note following when planning the electromagnetic compatibility of the cabinet:

• Generally, the fewer and smaller the holes in the cabinet, the better the interference attenuation. The maximum recommended diameter of a hole in galvanic metal contact in the covering cabinet structure is 100 mm. Pay special attention to the cooling air inlet and outlet gratings.

• The best galvanic connection between the steel panels is achieved by welding them together as no holes are necessary. If welding is not possible, the seams between the panels are recommended to be left unpainted and equipped with special conductive EMC strips to provide adequate galvanic connection. Usually, reliable strips are made of flexible silicon mass covered with a metal mesh. The non-tightened touch-contact of the metal surfaces is not sufficient, so a conductive gasket between the surfaces is required. The maximum recommended distance between assembly screws is 100 mm.

• Sufficient high-frequency grounding network must be constructed in the cabinet to avoid voltage differences and forming of high-impedance radiator structures. A good high-frequency grounding is made with short flat copper braids for low inductance. One-point high-frequency grounding cannot be used due to the long distances inside the cabinet.

• 360° high frequency grounding of the cable shields at the cable lead-throughs improves the EMC shielding of the cabinet.



40

• 360° high frequency grounding of the motor cable shields at their entries is recommended. The grounding can be implemented by a knitted wire mesh screening as shown below.

Bare cable shield

Cable ties

Knitted wire mesh

Lead-through plate

Cable

Cabinet bottom plate

• 360° high frequency grounding of the control cable shields is recommended at their entries. The shields can be grounded by means of conductive shielding cushions pressed against the cable shield from both directions:

Bare cable shield

Shielding cushion

(conductive)

Cabinet bottom plate

Cable

Cable grommet



Planning the grounding of the cable shields at the cabinet lead-through

Follow the principle shown in the figure below when planning the grounding of the cable shields at the cabinet lead-through.

To power terminals

Strain relief

41

Cable shield

PE terminal of the cabinet or drive module

EMC sleeve

Strip this part of the cable

Recommended for control cables

Example cable lead-through

Base plate

Lead-through plate

Planning the cooling

Note following guidelines when planning the cooling of the cabinet:

• The installation site must be sufficiently ventilated so that the cooling air flow and ambient temperature requirements of the drive module are met, see pages 117 and 122 . The internal cooling fan of the drive module rotates at a constant speed thus blowing constant air flow through the module. Whether the same amount of air must be replaced all the time in the facility depends on how much heat must be removed.

• The cabinet must have enough free space for the components to ensure sufficient cooling. Observe the minimum clearances given for each component. For the required free space around the drive module, see page 43 .

• The heat dissipated by cables and other additional equipment must also be ventilated.

• 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.



42

• 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

• The internal cooling fans of the drive modules and reactors/chokes 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.

• See page 117 for:

• allowed temperature rise inside the cabinet

• allowed pressure drop over the cabinet that the module fan can overcome

• air inlet and outlet sizes required for the module cooling and recommended filter material (if used).



43

Preventing the recirculation of hot air

Vertical air baffle

A

Air flow out

A

A - A

Drive module

Horizontal air baffle

Drive module

Air flow in max. 40°C (104 °F)

Drive cubicle from side Drive cubicle from above

Prevention the air recirculation 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.

Prevention the air recirculation inside the cabinet

Prevent hot air circulation inside the cabinet with eg, leak-proof air baffles at the positions shown in the diagrams in section Required free space around the drive module below. No gaskets are usually required.

Required free space around the drive module

Free space around the drive module is needed for ensuring that sufficient cooling air flows through the module and that the module cools properly.



44

Free space at top with high air inlet gratings in the cabinet door

The required free space at the top of the module is shown below when the air inlet gratings in the cabinet door are as high as the grating of the module. See also page 45 .

Air outlet on the cabinet roof

Air outlet in the cabinet door

200 mm

(7.87 in.)

300 mm

(11.81 in.)

Air baffles not required if the drive module touches the cabinet door

Free space at top with low air inlet gratings in the cabinet door

The required free space at the top of the module is shown below when the air inlet gratings are located only in the lower part of the cabinet door. Note: Air inlet gratings only at the lower part of the cabinet door are not recommended without an extra fan.

The air baffles are examples. See also page 45 .

Air outlet on the cabinet roof

200 mm

(7.87 in.)

Air outlet in the cabinet door

300 mm

(11.81 in.)

Air baffles



Free space at the side and front of the drive module

The figure below shows the required free space in a unit with motor and brake busbars connected to the left-hand side of the module. The required free space when no vertical busbars are used is also shown.

No extra space is needed at the back.

100 mm (3.94 in.)

Cables connected to the output busbars of the pedestal require

100 mm (3.94 in.) free space around the busbars for cooling.

45

50 mm (1.97 in.)

Cables connected to the vertical output busbar terminals require 50 mm (1.97 in.) free space around the busbar terminals for cooling.

Air inlet side

The required free space in front of the unit depends on the gratings in the cabinet door:

• 0 mm (0 in.) with air inlets as high as the grating in the module 1120 mm (44 in.)

• 150 mm (5.91 in.) with air inlets at the lower part of the cabinet only.

Other installation positions

Contact your local ABB representative.



46

Planning the placement of the control panel

Note the following alternatives when planning the placement of the control panel:

• The control panel can be snapped on the control unit of the drive. See page 28 .

• The control panel can be mounted onto the cabinet door using the control panel mounting kit (+J410). For the installation instructions, refer to ACS-CP-U Control

Panel IP54 Mounting Platform Kit (+J410) Installation Guide (3AUA0000049072

[English]).

Planning the use of the cubicle heaters

Use a cubicle 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.



47

Mechanical installation


This chapter describes how to install the drive module into a cabinet. First, beforeinstallation information is given, such as required tools, moving the unit and checking the delivery. Then, the mechanical installation procedure is described.

Safety

WARNING! The drive module is heavy 200 kg (441 lb).

Lift it by the upper part only using the lifting lugs attached to the top of the unit. The lower part will be deformed from lifting. Do not remove the pedestal before lifting.

Do not tilt the drive.

The centre of gravity of the unit is high.

The unit will overturn from a tilt of about 6 degrees. An overturning unit can cause physical injury.

M ax

3

0°

Do not lift by the lower part of the frame.

Do not tilt!

Mechanical installation


48

Checking the installation site

The material below the drive must be non-flammable and strong enough to carry the weight of the drive.

See chapter Technical data for the allowed operating conditions.

Required tools

• Set of screw drivers

• Torque wrench with a 500 mm (20 in.) or 2 × 250 mm (2 × 10 in.) long extension bar

• 19 mm (3/4 in.) socket, 17 mm (11/16 in.) magnetic-end socket

Moving and unpacking the unit

Move the transport package by pallet truck to the installation site.

The layout of the transport package is shown below.

A

D

B

C

B

4

5

1

6

7

6

Part no. Description

1 Drive module with factory installed options and multilingual residual voltage warning sticker

2

3

Output cable terminals with fastening screws

Floor fastening brackets and PE terminals with screws

4 • Control unit with control cable clamp plate, control panel options (+J400, +J410, +J414) and factory installed optional modules

5

6

7

• Delivery documents

• Printed Hardware Manual and

Quick Start-up Guide, other printed manuals if ordered, manuals CD

• Optional module manuals

Sheathing

PP cushion

Pallet 6 2

3

6



49

Unpack the package as follows:

• Cut the bands (A).

• Unpack the additional boxes (B).

• Remove the sheathing by lifting it (C).

• Fasten lifting hooks to the drive module lifting eyes (D) and lift the module to the installation place.

Checking the delivery

Check that all items listed under section Moving and unpacking the unit are present.

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

Attaching the warning stickers

Attach the residual voltage warning sticker of the local language onto the drive module front cover.



50

Fastening the cable lug terminals to the output busbars

1. Fasten the grounding terminals to the long side plates of the pedestal with screws.

2. Fasten the cable lug terminals to the busbars with screws.

WARNING!

See the next page for the screw sizes and tightening torques!

2

2

1

Side view (cable lug terminals fastened)



M10x25

M10x25 M10x 20

2

2

2

2

2

2

2

2

2

2

W2 V2 U2 R-

R+

UDC+

UDC -

2

2

M10

2 pcs

1

Tightening torques:

M10: 30...44 N·m

(22...32 lbf·ft)

M12: 50...75 N·m

(37...55 lbf·ft)

WARNING! Fasten the output busbars to the insulating supports with M10x20 screws when no cable lug terminal is connected, but with M10x25 screws when a cable lug terminal is connected as well. Screwing an M10x25 screw without a cable lug terminal through the busbar into the insulating support will break the insulating support.

Insulating support

M10x20

Cable lug terminal

M10x25 M10x25

51



52

Fastening the drive module to the cabinet base

1. Fasten the front fastening bracket to the drive module pedestal with two screws.

2. Fasten the back fastening bracket onto the cabinet base with two screws.

3. Place the drive module on the cabinet base and push it so that the tabs of the fastening bracket enter the slots in the drive module pedestal.

4. Fasten the front bracket to the base with two screws.

4

4

1

1

M8 (5/16 in.)

Tightening torque: 5 N·m (3.7 lbf·ft)

WARNING!

Place the module on a solid base. The fastening brackets are not strong enough to carry the weight of the module on their own.



53

Installing the drive control unit

The drive control unit can be fastened on a mounting plate through the fastening holes in its back or by using a DIN rail. The following drawings show the control unit with front cover but units without covers are installed in the same way.

Mounting through the fastening holes

1. Fasten the fastening screws in the wall.

2. Lift the unit onto the screws.

1

2

2

3aua0000038989



54

Vertical DIN rail mounting

1. Fasten the latch (A) to the back of the control unit with four screws.

2. Click the control unit to the rail as shown below (B).

A

A

B

B

3aua0000038989



Horizontal DIN rail mounting

1. Fasten the latches (A) to the back of the control unit with four screws.

2. Click the control unit to the rail as shown below (B).

55

A

A

B

B

B

B

3aua0000038989



56



57

Planning the electrical installation


This chapter contains the instructions that you must follow when selecting the motor, cables, protections, cable routing and way of operation for the drive system.

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. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.

Selecting the supply disconnecting device (disconnecting means)

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.

European Union

To meet the European Union Directives, according to standard EN 60204-1, Safety of Machinery , the disconnecting device must be one of the following types:

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

• 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)

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

Other regions

The disconnecting device must conform to the applicable safety regulations.

Selecting and dimensioning the main contactor

If a main contactor is used, its utilization category (number of operations under load) must be AC-1 according to IEC 60947-4, Low-voltage switchgear and controlgear .

Dimension the main contactor according to the nominal voltage and current of the drive.

Planning the electrical installation


58

Checking the compatibility of the motor and drive

Use an AC induction motor or a permanent magnet synchronous motor with the drive. Several induction motors can be connected at a time but only one permanent magnet motor.

Select the motor and drive according to the rating tables in chapter Technical Data .

Use the DriveSize PC tool if the default load cycles are not applicable.

1. Check that the motor ratings lie within the allowed ranges of the drive control program:

• motor nominal voltage is in the range of 1/2...2 · U

N

• motor nominal current is 1/6 ... 2 ·

0 ... 2 · I

Hd

I

Hd

of the drive in DTC control and

in scalar control. The control mode is selected by a drive parameter.

2. Check that the motor voltage rating meets the application requirements:

When

No resistor braking is in use

Frequent or long term brake cycles will be used

… the motor voltage rating should be …

U

N

1.21

· U

N

U

N

input voltage of the drive

See note 6 below the Requirements table , page 61.

3. Consult the motor manufacturer before using a motor in a drive system where the motor nominal voltage differs from the AC power source voltage.

4. Ensure that the motor insulation system withstands the maximum peak voltage in the motor terminals. See the Requirements table below for the required motor insulation system and drive filtering.

Example 1: When the supply voltage is 440 V and the drive is operating in motor mode only, the maximum peak voltage in the motor terminals can be approximated as follows: 440 V · 1.35 · 2 = 1190 V. Check that the motor insulation system withstands this voltage.

Protecting the motor insulation and bearings

The drive employs modern IGBT inverter technology. Regardless of frequency, the drive output comprises pulses of approximately the drive DC bus voltage with a very short rise time. The pulse voltage can almost double at the motor terminals, depending on the attenuation and reflection properties of the motor cable and the terminals. This can cause additional stress on the motor and motor cable insulation.

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

Optional du/dt filters protect motor insulation system and reduce bearing currents.

Common mode filters mainly reduce bearing currents.



59

A

B

B

To avoid damage to motor bearings:

• select and install the cables according to the instructions given in the hardware manual

• use insulated N-end (non-drive end) bearings and output filters from ABB according to the Requirements table below.

Requirements table

The following table shows how to select the motor insulation system and when an optional ABB du/dt filter, insulated N-end (non-drive end) motor bearings and ABB common mode filters are required. The motor manufacturer should be consulted regarding the construction of the motor insulation and additional requirements for explosion-safe (EX) motors. Failure of the motor to fulfil the following requirements or improper installation may shorten motor life or damage the motor bearings and voids the warranty.

Motor type

Randomwound M2_ and M3_

Form-wound

HX_ and AM_

Old* formwound HX_ and modular

Randomwound HX_ and AM_ **

Nominal AC line voltage

Motor insulation system

-

Requirement for

ABB du/dt filter, insulated N-end bearing and ABB common mode filter

P

N frame size < IEC 315

P

N

< 134 hp and frame size <

NEMA 500

+ du/dt

< 100 kW and

100 kW < P

N or

< 350 kW frame size > IEC 315

134 hp < P or frame size >

NEMA 500

+ N

+ du/dt + N

N

< 469 hp

P

N

> 350 kW or frame size > IEC 400

P

N

> 469 hp or frame size >

NEMA 580

+ N + CMF

+ du/dt + N + CMF

U

N

< 500 V Standard

500 V < U

N

< 600 V Standard or

Reinforced

600 V < U

N

< 690 V Reinforced

380 V < U

N

< 690 V Standard

-

+ du/dt n.a.

+ N

+ du/dt + N

+ N + CMF

+ N + CMF

+ du/dt + N + CMF

P

N

< 500 kW: + N +

CMF

P

N

> 500 kW: + N +

CMF + du/dt

380 V < U

N

< 690 V Check with the motor manufacturer.

0 V < U

N

< 500 V

500 V < U

N

< 690 V

Enamelled wire with fiber glass taping

+ du/dt with voltages over 500 V + N + CMF

+ N + CMF

+ du/dt + N + CMF



60

Motor type

A

B

B

N

-

N

O

Randomwound and form-wound

Nominal AC line voltage


-

Requirement for


P

N

< 100 kW and frame size < IEC 315

P

N

< 134 hp and frame size <

NEMA 500

100 kW < P

N or

< 350 kW frame size > IEC 315

134 hp < P or frame size >

NEMA 500

+ N or CMF

N

< 469 hp

P

N

> 350 kW or frame size > IEC 400

P

N

> 469 hp or frame size >

NEMA 580

+ N + CMF U

N

< 420 V Standard: Û

LL

1300 V

=

420 V < U

N

< 500 V Standard: Û

LL

1300 V

= + du/dt + du/dt + N or

+ du/dt + CMF

+ du/dt + N + CMF or

Reinforced: Û

LL

1600 V, 0.2

= microsecond rise time

-

500 V < U

N

< 600 V Reinforced: Û

LL

1600 V

= + du/dt

+ N or CMF

+ du/dt + N or

+ du/dt + CMF

+ N + CMF

+ du/dt + N + CMF or

Reinforced: Û

LL

1800 V

= -

600 V < U

N

< 690 V Reinforced: Û

LL

1800 V

= + du/dt

Reinforced: Û

LL

2000 V, 0.3

= microsecond rise time ***

-

+ N or CMF

+ du/dt + N

N + CMF

+ N + CMF

+ du/dt + N + CMF

N + CMF

* manufactured before 1.1.1998

** For motors manufactured before 1.1.1998, check for additional instructions with the motor manufacturer.

*** If the intermediate DC circuit voltage of the drive is increased from the nominal level by resistor braking , check with the motor manufacturer if additional output filters are needed in the applied drive operation range.

Note 1: The abbreviations used in the table are defined below.

Abbreviation

U

N

Û

LL

P

N du/dt

CMF

N n.a.

Definition

Nominal voltage of the supply network

Peak line-to-line voltage at motor terminals which the motor insulation must withstand

Motor nominal power du/dt filter at the output of the drive +E205

Common mode filter +E208

N-end bearing: insulated motor non-drive end bearing

Motors of this power range are not available as standard units. Consult the motor manufacturer.



61

A

B

B

Motor type

Randomwound

Note 2: Explosion-safe (EX) motors

The motor manufacturer should be consulted regarding the construction of the motor insulation and additional requirements for explosion-safe (EX) motors.

Note 3: High-output motors and IP 23 motors

For motors with higher rated output than what is stated for the particular frame size in EN 50347 (2001) and for IP23 motors, the requirements of ABB random-wound motor series (for example M3AA, M3AP,

M3BP) are given below. For non-ABB motor types, see the Requirements table above. Apply the requirements of range 100 kW < P

N range P

N

> 350 kW to motors within the range 100 kW < P motor manufacturer.

< 350 kW to motors with P

N

< 100 kW. Apply the requirements of

N

< 350 kW . In other cases, consult the

Nominal mains voltage (AC line voltage)

U

N

< 500 V


Standard

500 V < U

N

< 600 V Standard or

Reinforced

600 V < U

N

< 690 V Reinforced

Requirement for


P

N

< 100 kW

P

N

< 140 hp

100 kW < P

140 hp < P

N

N

< 200 kW

< 268 hp

P

P

N

N

> 200 kW

> 268 hp

-

+ du/dt

+ N

+ du/dt + N

+ N + CMF

+ du/dt + N + CMF

-

+ du/dt

+ N

+ du/dt + N

+ N + CMF

+ du/dt + N + CMF

Note 4: HXR and AMA motors

All AMA machines (manufactured in Helsinki) for drive systems have form-wound windings. All HXR machines manufactured in Helsinki starting 1.1.1998 have form-wound windings.

Note 5: ABB motors of types other than M2_, M3_, HX_ and AM_

Use the selection criteria given for non-ABB motors.

Note 6: Resistor braking of the drive

When the drive is in braking mode for a large part of its operation time, the intermediate circuit DC voltage of the drive increases, the effect being similar to increasing the supply voltage by up to

20 percent. The voltage increase should be taken into consideration when determining the motor insulation requirement.

Example: Motor insulation requirement for a 400 V application must be selected as if the drive were supplied with 480 V.

Note 8: Calculating the rise time and the peak line-to-line voltage

The peak line-to-line voltage at the motor terminals generated by the drive as well as the voltage rise time depend on the cable length. The requirements for the motor insulation system given in the table are “worst case” requirements covering installations with 30 metre and longer cables. The rise time can be calculated as follows: t = 0.8 · Û

LL

/(du/dt). Read the values of the graph by the supply voltage ( U

Û

LL

and du/dt from the diagrams below. Multiply

N

). In case of drives with resistor braking, the Û

LL

and du/dt values are approximately 20% higher.



62

3.0

2.5

2.0

1.5

1.0

0.5

0.0

Û

LL

/ U

N du/dt

U

N

μ s)

2.0

1.5

1.0

5.5

5.0

4.5

4.0

3.5

3.0

2.5

du/dt

U

N

μ s)

Û

LL

/ U

N

100 200 300

Cable length (m)

With du/dt filter

100 200 300

Cable length (m)

Without du/dt filter

Note 9: Sine filters protect the motor insulation system. Therefore, du/dt filter can be replaced with a sine filter. The peak phase-to-phase voltage with the sine filter is approximately 1.5 · U

N

.

Note 10: Common mode filter is available as a plus code option (+E208) or as a separate kit (one box including three rings for one cable).

Selecting the power cables

General rules

Dimension the input power and motor cables according to local regulations :

• Dimension the cable to carry the drive load current. See chapter Technical data for the rated currents.

• Select a cable rated for at least 70

°

C maximum permissible temperature of conductor in continuous use. For US, see Additional US requirements, page 65 .

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

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

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

Use symmetrical shielded motor cable, see page 65 . Ground the shield(s) of motor cable(s) 360° at both ends.

Note: When continuous metal conduit is employed, shielded cable is not required.

The conduit must have bonding at both ends as with cable shield.



63

A four-conductor system is allowed for input cabling, but shielded symmetrical cable is recommended. To operate as a protective conductor, the shield conductivity requirements according to IEC 60439-1 are shown below when the protective conductor is made of the same metal as the phase conductors:

Cross-sectional area of the phase conductors

S (mm

2

)

S < 16

16 < S < 35

35 < S

Minimum cross-sectional area of the corresponding protective conductor

S p

(mm

2

)

S

16

S/2

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

Keep the motor cable and its PE pigtail (twisted shield) as short as possible to reduce high-frequency electromagnetic emissions.

Typical power cable sizes

The table below gives copper and aluminium cable types for different load currents.

Cable sizing is based on max. 9 cables laid on a cable ladder side by side, three ladder type trays one on top of the other, ambient temperature 30 °C, PVC insulation, surface temperature 70 °C (EN 60204-1 and IEC 60364-5-52/2001). For other conditions, dimension the cables according to local safety regulations, appropriate input voltage and the load current of the drive.

Copper cables with concentric copper shield

Max. load current

A

274

Cable type mm

2

2 × (3×70)

334

386

2 × (3×95)

2 × (3×120)

446

510

602

579

669

765

903

2 × (3×150)

2 × (3x185)

2 × (3×240)

3 × (3×120)

3 × (3×150)

3 × (3×185)

3 × (3×240)

Aluminium cables with concentric copper shield


A

302

Cable type mm

2

2 × (3×120)

348

398

2 × (3×150)

2 × (3×185)

470

522

597

705

2 × (3×240)

3 × (3×150)

3 × (3×185)

3 × (3×240)

3BFA 01051905 C



64

Typical power cable sizes (US)

Cable sizing is based on NEC Table 310-16 for copper wires, 75 °C (167 °F) wire insulation at 40 °C (104 °F) ambient temperature. Not more than three currentcarrying conductors in raceway or cable or earth (directly buried). For other conditions, dimension the cables according to local safety regulations, appropriate input voltage and the load current of the drive.

Copper cables with concentric copper shield


A

273

295

Cable type

AWG/kcmil

350 MCM or 2 × 2/0

400 MCM or 2 × 2/0

334

370

405

449

502

500 MCM or 2 × 3/0

600 MCM or 2 × 4/0 or 3 × 1/0

700 MCM or 2 × 4/0 or 3 × 2/0

2 × 250 MCM or 3 × 2/0

2 × 300 MCM or 3 × 3/0

546

590

669

739

810

884

1003

1109

1214

2 × 350 MCM or 3 × 4/0

2 × 400 MCM or 3 × 4/0

2 × 500 MCM or 3 × 250 MCM

2 × 600 MCM or 3 × 300 MCM

2 × 700 MCM or 3 × 350 MCM

3 × 400 MCM or 4 × 250 MCM

3 × 500 MCM or 4 × 300 MCM

3 × 600 MCM or 4 × 400 MCM

3 × 700 MCM or 4 × 500 MCM



Alternative power cable types

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

Recommended

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

PE conductor and shield

Shield

A separate PE conductor is required if the conductivity of the cable shield is < 50% of the conductivity of the phase conductor.

Shield

PE

PE

65

PE

Shield

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

Not allowed for motor cables Not allowed for motor cables with phase conductor cross section larger than 10 mm

2

(motors > 30 kW [40 hp]).

Motor cable shield

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 or copper wire.

The better and tighter the shield, the lower the emission level and bearing currents.

Insulation jacket

Copper wire screen Helix of copper tape or copper wire

Inner insulation

Cable core

Additional US requirements

Use type MC continuous corrugated aluminum armor cable with symmetrical grounds or shielded power cable for the motor cables if metallic conduit is not used.

For the North American market, 600 V AC cable is accepted for up to 500 V AC. For drives rated over 100 amperes, the power cables must be rated for 75

°

C (167

°

F).



66

Conduit

Couple separate parts of a conduit together: bridge the joints with a ground conductor bonded to the conduit on each side of the joint. Bond the conduits also to the drive enclosure and motor frame. Use separate conduits for input power, motor, brake resistor, and control wiring. When conduit is employed, type MC continuous corrugated aluminium armor cable or shielded cable is not required. A dedicated ground cable is always required.

Note : Do not run motor wiring from more than one drive in the same conduit.

Armored cable / shielded power cable

Six conductor (3 phases and 3 ground) type MC continuous corrugated aluminum armor cable with symmetrical grounds is available from the following suppliers (trade names in parentheses):

• Anixter Wire & Cable (Philsheath)

• BICC General Corp (Philsheath)

• Rockbestos Co. (Gardex)

• Oaknite (CLX).

Shielded power cables are available from Belden, LAPPKABEL (ÖLFLEX) and

Pirelli.

Selecting the control cables

Shielding

All control cables must be shielded.

Use a double-shielded twisted pair cable for analogue signals. This type of cable is recommended for the pulse encoder signals also. Employ one individually shielded pair for each signal. Do not use common return for different analogue signals.

A double-shielded cable is the best alternative for low-voltage digital signals but single-shielded twisted pair cable (Figure b) is also usable.

a

A double-shielded twisted pair cable b

A single-shielded twisted pair cable



67

Signals in separate cables

Run analogue and digital signals in separate, shielded cables.

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

Signals allowed to be run in the same cable

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.

Relay cable type

The cable type with braided metallic screen (for example ÖLFLEX by LAPPKABEL,

Germany) has been tested and approved by ABB.

Control panel cable length and type

In remote use, the cable connecting the control panel to the drive must not exceed 3 meters (10 ft). The cable type tested and approved by ABB is used in control panel option kits.

Routing the cables

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

Where control cables must cross power cables ensure 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.



68

Diagram

A diagram of the cable routing is shown below.

Drive

Motor cable

Power cable min 300 mm (12 in.)

Input power cable min 200 mm (8 in.)

90 °

Control cables

Motor cable, brake cable min 500 mm (20 in.)

Separate control cable ducts

24 V

230 V

(120 V) 24 V

230 V

(120 V)

Not allowed unless the 24 V cable is insulated for 230 V (120 V) or insulated with an insulation sleeving for 230 V

(120 V).

Lead 24 V and 230 V (120 V) control cables in separate ducts inside the cabinet.



69

Continuous motor cable shield or enlosure for equipment in the motor cable

To minimize the emission level when safety switches, contactors, connection boxes or similar equipment are installed in the motor cable between the drive and the motor:

• European Union: Install the equipment in a metal enclosure with 360 degrees grounding for the shields of both the incoming and outgoing cable, or connect the shields of the cables otherwise together.

• US: Install the equipment in a metal enclosure in a way that the conduit or motor cable shielding runs consistently without breaks from the drive to the motor.

Implementing thermal overload and short-circuit protection

Protecting the drive and input power cable in short-circuits

Protect the drive and input cable with fuses or a circuit breaker as follows:

Drive module Distribution board

1)

Input cable

~

~

M

3~

2)

~

~

M

3~

1. Size the fuses according to instructions given in chapter Technical data.

The 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.

2. Circuit breakers which have been tested by ABB with the drive can be used.

Fuses must be used with other circuit breakers. Contact your local ABB representative for the approved breaker types and supply network characteristics.

The protective characteristics of circuit breakers depend on the type, construction and settings of the breakers. There are also limitations pertaining to the shortcircuit capacity of the supply network.



70

WARNING!

Due to the inherent operating principle and construction of circuit breakers, independent of the manufacturer, hot ionized gases may escape from the breaker enclosure in case of a short-circuit. To ensure safe use, special attention must be paid to the installation and placement of the breakers. Follow the manufacturer’s instructions.

Note: Circuit breakers must not be used without fuses in the USA.

Protecting the motor and motor cable in short-circuits

The drive protects the motor cable and 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.

Protecting the drive and the input power and motor cables against thermal overload

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

Protecting the motor against thermal overload

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

The most common temperature sensors are:

• motor sizes IEC180…225: thermal switch eg, Klixon

• motor sizes IEC200…250 and larger: PTC or Pt100.

See the Firmware Manual for more information on the motor thermal protection, and the connection and use of the temperature sensors.



71

Protecting the drive against ground faults

The drive is equipped with an internal ground fault protective function to protect the unit against ground faults in the motor and 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 .

Measures for protection in case of direct or indirect contact, such as separation from the environment by double or reinforced insulation or isolation from the supply system by a transformer, can be applied.

Residual current device compatibility

The drive is suitable to be used with residual current devices of Type B.

Note: The EMC filter of the drive 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.

Implementing the Emergency stop function

For safety reasons, install the emergency stop devices at each operator control station and at other operating stations where emergency stop may be needed.

Note: Pressing the stop key ( ) on the control panel of the drive does not generate an emergency stop of the motor or separate the drive from dangerous potential.

Implementing the Safe Torque Off function

The drive supports the Safe Torque Off function according to standards

EN 61800-5-2:2007; EN 954-1:1997; IEC/EN 60204-1:1997; EN 61508:2002 and

EN 1037:1996.

The Safe Torque Off function disables the control voltage of the power semiconductors of the drive output stage, thus preventing the inverter from generating the voltage required to rotate the motor (see diagram below). By using this function, short-time operations (like cleaning) and/or maintenance work on nonelectrical parts of the machinery can be performed without switching off the power supply to the drive.



72

ACS850-04

+24 V

Safe Torque Off connection on JCU

XSTO:1

XSTO:2

Activation switch

XSTO:3

XSTO:4

UDC+

Control circuit

Output stage

(1 phase shown)

UDC-

U2/V2/W2

Notes:

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

• The maximum cable length between the drive and the activation switch is 25 m

(82 ft)

WARNING!

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

Note: It is not recommended to stop the drive by using the Safe Torque Off function.

If a running drive is stopped by using the Safe Torque Off function, the drive will stop by coasting. If this is not acceptable eg, causes danger, the drive and machinery must be stopped using the appropriate stopping mode before using this function.

Note concerning permanent magnet motor drives in case of a multiple IGBT power semiconductor failure: In spite of the activation of the Safe Torque Off function, the drive system can produce an alignment torque which maximally rotates the motor shaft by 180/ p degrees. p denotes the pole pair number.

Implementing the Power-loss ride-through function

The Power-loss ride-through function is activated when parameter

47.02 UNDERVOLTAGE CTRL is set to ON (default in Standard Control Program).

Note: If the drive is equipped with a line contactor, it opens in a power loss and must be closed again by a time relay.



73

Using power factor compensation capacitors with the drive

Power factor compensation is not needed with AC drives. However, if a drive is to be connected in a system with compensation capacitors installed, note the following restrictions.

WARNING!

Do not connect power factor compensation capacitors or harmonic filters to the motor cables (between the drive and the motor). They are not meant to be used with AC drives and can cause permanent damage to the drive or themselves.

If there are power factor compensation capacitors in parallel with the three phase input of the drive:

1. Do not connect a high-power capacitor to the power line while the drive is connected. The connection will cause voltage transients that may trip or even damage the drive.

2. If capacitor load is increased/decreased step by step when the AC drive is connected to the power line, ensure that the connection steps are low enough not to cause voltage transients that would trip the drive.

3. Check that the power factor compensation unit is suitable for use in systems with

AC drives ie, harmonic generating loads. In such systems, the compensation unit should typically be equipped with a blocking reactor or harmonic filter.

Implementing a safety switch between the drive and motor

It is recommended to install a safety switch between the permanent magnet synchronous motor and the drive output. The switch is needed to isolate the motor during any maintenance work on the drive.

Using a contactor between the drive and the motor

Arrange the control of the output contactor by applying one of the alternatives described below.

Alternative 1: When you have selected to use the default motor control mode (DTC) and motor coast stop in the drive, open the contactor as follows:

1. Give a stop command to the drive.

2. Open the contactor.

Alternative 2: When you have selected to use the default motor control mode (DTC) and motor ramp stop in the drive, open the contactor as follows:


2. Wait until the drive decelerates the motor to zero speed.




74

Alternative 3: When you have selected to use the scalar motor control mode in the drive, open the contactor as follows:



WARNING!

When you have the default motor control mode (DTC) in use, never open the output contactor while the drive rotates the motor. The DTC motor control operates extremely fast, much faster than it takes for the contactor to open its contacts. When the contactor starts opening while the drive rotates the motor, the

DTC will try to maintain the load current by immediately increasing the drive output voltage to the maximum. This will damage, or even burn the contactor completely.

Implementing a bypass connection

If bypassing is required, employ mechanically or electrically interlocked contactors between the motor and the drive and between the motor and the power line. Ensure with the interlocking that the contactors cannot be closed simultaneously.

Follow this control sequence:

1. Stop the drive.

2. Stop the motor.

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

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



75

An example bypass connection is shown below.

Switch Description

S11 Drive main contactor on/off control

S40 Motor power supply selection (drive or direct on line)

S41

S42

Start when motor is connected on line

Stop when motor is connected direct on line

WARNING!

Never connect the supply power to the drive output terminals U2, V2 and W2. Line voltage applied to the output can result in permanent damage to the unit.

Protecting the contacts of relay outputs

Inductive loads (relays, contactors, motors) cause voltage transients when switched off.

The relay contacts on the JCU Control Unit are protected with varistors (250 V) against overvoltage peaks. In spite of this, it is highly recommended to equip inductive loads with noise attenuating circuits (varistors, RC filters (AC) or diodes

(DC)) in order to minimize the EMC emission 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.



76

Install the protective component as close to the inductive load as possible. Do not install protective components at the relay outputs.

Varistor

230 VAC

Relay output

RC filter

230 VAC

Relay output

Diode

24 VDC

Relay output

Connecting a motor temperature sensor to the drive I/O

WARNING! IEC 60664 requires double or reinforced insulation between live parts and the surface of accessible parts of electrical equipment which are either nonconductive or conductive but not connected to the protective earth.

To fulfil this requirement, the connection of a thermistor (and other similar components) to the digital inputs of the drive can be implemented in three alternate ways:

1. There is double or reinforced insulation between the thermistor and live parts of the motor.

2. Circuits connected to all digital and analogue inputs of the drive are protected against contact and insulated with basic insulation (the same voltage level as the drive main circuit) from other low voltage circuits.

3. An external thermistor relay is used. The insulation of the relay must be rated for the same voltage level as the main circuit of the drive. For connection, see

Firmware Manual .

Example circuit diagram

See page 136 .



77

Electrical installation


This chapter instructs in the cabling of the drive.

Warnings

WARNING!

Only qualified electricians are allowed to carry out the work described in this chapter. Follow the Safety instructions on the first pages of this manual. Ignoring the safety instructions can cause injury or death.

Checking the insulation of the assembly

Drive

Every drive module has been tested for insulation between the main circuit and the chassis (2500 V rms 50 Hz for 1 second) at the factory. Therefore, do not make any voltage tolerance or insulation resistance tests (e.g. hi-pot or megger) on any part of the drive.

Input cable

Check the insulation of the input cable according to local regulations before connecting it 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 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.

ohm

U1

V1

M

3~

W1 PE

Electrical installation


78

Brake resistor and resistor cable

Check the insulation of the brake 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+ ohm

R-

PE

Checking the combatibility with IT (ungrounded) and TN (corner grounded) systems

A drive equipped with no EMC filter or with optional EMC filter +E210 is suitable for

IT (ungrounded) and TN (grounded) systems.



79

Connecting the power cables

Connection diagram

2)

PE

3)

INPUT

U1 V1 W1

Drive module

R

-

UDC+

R+

UDC

OUTPUT

U2 V2 W2

(PE) PE (PE)

1)

5)

4)

L1 L2 L3

7) External brake resistor, see page 137 .

8)

5)

V1

U1

3

~

Motor

W1

6)

1) For alternatives, see section Selecting the supply disconnecting device (disconnecting means) on page 57.

2) If shielded cable is used (not required but recommended) and the conductivity of the shield is < 50% of the conductivity of the phase conductor, use a separate PE cable (2) or a cable with a grounding conductor (3).

3) as 2)

4) 360 degrees grounding is recommended at the cabinet entry if shielded cable is used. Ground the other end of the input cable shield or PE conductor at the distribution board.

5) 360 degrees grounding at the cabinet entry is recommended, see page 39.

6) Use a separate grounding cable if the conductivity of the cable shield is < 50% of the conductivity of the phase conductor and there is no symmetrically constructed grounding conductor in the cable

(see page 65 ).

7) External brake resistor, see page 137 .

8) du/dt filter or sine filter (optional, see page 143 ).

Note:

If there is a symmetrically constructed grounding conductor in the motor cable in addition to the conductive shield, connect the grounding conductor to the grounding terminal at the drive and motor ends.

Do not use an asymmetrically constructed motor cable. Connecting its fourth conductor at the motor end increases bearing currents and causes extra wear.



80

Input cable connection procedure

Connect the input cable phase conductors to the drive module terminals U1, V1 and

W1 and the PE conductor to the PE terminal. Connect the twisted shield of the input cable to the PE terminal even if it is not used as the PE conductor.

V1

U1

W1

PE

Removing the protective covering

The protective covering on top of the drive module prevents dust from borings and grindings from entering the module when installing. The covering is used because electrically conductive dust inside the unit may cause damage or malfunctioning.

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



Motor cable connection procedure

1. Connect the twisted shield of the motor cable to the grounding terminal with a cable lug.

2. Connect the phase conductors to the cable lug terminals U2, V2 and W2.

81

W2 V2 U2

1

1

2

2

It is recommended to ground the motor cable shield 360° at the cabinet cable entry, see page 41 .



82

For minimum radio frequency interference, ground the motor cable shield at the motor end as follows:

• 360 degrees at the lead-through of the motor terminal box

360 degrees grounding

Conductive gaskets

• or by twisting the shield as follows: flattened width > 1/5 · length. a b b > 1/5 · a

DC connection

The UDC+ and UDC– terminals are intended for common DC configurations of a number of drives, allowing regenerative energy from one drive to be utilised by the other drives in motoring mode. Contact your local ABB representative for further instructions.

Checking the settings of the cooling fan transformer

The voltage transformer of the cooling fan is located at the top right-hand corner of the drive module. Remove the front cover for adjusting the settings and replace the cover after setting.

Set to 220 V if the supply frequency is 60 Hz. Set to

230 V if the supply frequency is 50 Hz.

Set according to the supply voltage range:

380 V, 400 V, 415 V, 440 V, 480 V or 500 V;



83

Removing the cover assembly

The cover assembly needs to be removed before the installation of optional modules and the connection of control cabling. Follow this procedure to remove the cover assembly. The numbers refer to the illustrations below.

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

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

• Disconnect the panel cable (3) if present.

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

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

Refit the cover in reverse order to the above procedure.

4

2

1

5

3



84

Fastening the control cable clamp plate

Fasten the control cable clamp plate either to the top or base of the control unit with four screws as shown below.

0.7 N·m

(6.2 lbf·in)

Grounding the control unit

If the control unit is not grounded through DIN rail mounting, connect the APOW cable grounding wire to the grounding terminal at the back top or bottom of the control unit.

A grounding terminal is provided at the base and top of the control unit back frame.



85

Connecting the control unit to the drive module

Connect the control unit to the drive module as follows.

WARNING!

Handle the fiber optic cables with care. When unplugging optic cables, always grab the connector, not the cable itself. Do not touch the ends of the fibers with bare hands as the fiber is extremely sensitive to dirt.

1. Lift the control unit from the mounting place, turn it upside down and thread the fiber optic cables inside the back frame of the unit as shown below.

JRIB board terminals are located inside the back frame of the control unit.

3AUA0000038989



86

2. Insert the fiber optic cables to the JRIB board terminals.

3. Connect the power supply cable coming from the drive module to the cable connected to the JRIB board terminals.

APOW board

3

JINT board

V1

V2

V6

V7

Connection table

APOW JRIB

X3: 1 X202: 1

X3: 2

JINT

X202: 2

JRIB

V1

V2

V6

V7

JRIB board

2

1

V2

V1

V7

V6

2

TXD = transmitter RXD = receiver

Connecting the control cables

See sections Default I/O connection diagram and Control cable connection procedure below.



87

Default I/O connection diagram

Notes:

[…] denotes default setting with ACS850 standard control program (Factory macro).

See Firmware Manual for other macros.

*Total maximum current: 200 mA

The wiring shown is for demonstrative purposes only. Further information of the usage of the connectors and jumpers are given in the text; see also the chapter

Technical data .

Wire sizes and tightening torques:

XPOW, XRO1, XRO2, XRO3, XD24:

0.5 … 2.5 mm

2

(24…12 AWG). Torque:

0.5 N·m (5 lbf·in)

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

0.5 … 1.5 mm

2

(28…14 AWG). Torque:

0.3 N·m (3 lbf·in)

Order of terminal headers and jumpers

XPOW

(2-pole, 2.5 mm 2 )

XRO1

(3-pole, 2.5 mm 2 )

XRO2

(3-pole, 2.5 mm

2

)

XRO3

(3-pole, 2.5 mm

2

)

XD24

(4-pole, 2.5 mm

2

)

DI/DIO grounding selection

XDI

(7-pole, 1.5 mm

2

)

XDIO

(2-pole, 1.5 mm 2 )

XAI

(7-pole, 1.5 mm 2 )

AI1, AI2

XAO

(4-pole, 1.5 mm 2 )

T

XD2D

(3-pole, 1.5 mm

2

)

XSTO (orange)

(4-pole, 1.5 mm

2

)

External power input

24 V DC, 1.6 A

Relay output RO1 [Ready]

250 V AC / 30 V DC

2 A

Relay output RO2 [Modulating]

250 V AC / 30 V DC

2 A

Relay output RO3 [Fault(-1)]

250 V AC / 30 V DC

2 A

+24 V DC*

Digital input ground

+24 V DC*

Digital input/output ground

Ground selection jumper

Digital input DI1 [Stop/Start]

Digital input DI2

Digital input DI3 [Reset]

Digital input DI4

Digital input DI5

Digital input DI6 or thermistor input

Start interlock (0 = Stop)

Digital input/output DIO1 [Output: Ready]

Digital input/output DIO2 [Output: Running]

Reference voltage (+)

Reference voltage (–)

Ground

Analog input AI1 (Current or voltage, selectable by jumper AI1) [Speed reference 1]

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

+24VI

XPOW

1

GND 2

XRO1, XRO2, XRO3

NO

COM

NC

NO

COM

NC

NO

COM

NC

8

9

XD24

+24VD

DIGND

+24VD 3

DIOGND 4

AI1

XDI

1 DI1

DI2

DI3

DI4

2

3

4

1

2

3

4

5

1

2

6

7

DI5

DI6

DIIL

DIO1

DIO2

5

6

A

XDIO

1

2

XAI

+VREF

-VREF

AGND

AI1+

AI1-

AI2+

AI2-

AI1 current/voltage selection jumper

AI2 current/voltage selection jumper

6

7

AI1

AI2

XAO

1

2

3

4

5

Analog output AO1 [Current %]

Analog output AO2 [Speed %]

Drive-to-drive link termination jumper

Drive-to-drive link.

Safe Torque Off. Both circuits must be closed for the drive to start.

AO1+

AO1-

AO2+

AO2-

B

A

BGND

OUT1

OUT2

IN1

IN2

1

2

3

4

XD2D

T

1

2

3

XSTO

1

2

3

4

Control panel connection

Memory unit connection



88

Jumpers

DI/DIO grounding selector (located between XD24 and XDI) – Determines whether the DIGND (ground for digital inputs DI1…DI5) floats, or if it is connected to DIOGND

(ground for DI6, DIO1 and DIO2). See the JCU isolation and grounding diagram on page 121 .

If DIGND floats, the common of digital inputs DI1…DI5 should be connected to

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

cc

as DI1…DI5 are of the NPN/PNP

DIGND floats DIGND tied to DIOGND

2

3

4

2

3

4

1

2

1

2

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

Current Voltage

7

AI1

AI2

1

7

AI1

AI2

1

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

Current Voltage

7

AI1

AI2

1

7

AI1

AI2

1

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

Termination ON Termination OFF

T T



89

External power supply for the JCU Control Unit (XPOW)

External +24 V (minimum 1.6 A) power supply for the control unit can be connected to terminal block XPOW. Using an external supply is recommended if

• the application requires fast start after connecting the drive to the main supply

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

DI6 (XDI:6) as a thermistor input

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

One sensor Three sensors

Motor

XDI:6

XD24:1

Motor

XDI:6

XD24:1

T 3.3 nF

> 630 VAC

T T T

3.3 nF

> 630 VAC

Notes:

• Do not connect both ends of the cable shields directly to ground. If a capacitor cannot be used at one end, leave that end of the shield unconnected.

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

Firmware Manual of the drive.

• PTC (as well as KTY84) sensors can alternatively be connected to a FEN-xx encoder interface. See the User’s Manual of the interface for wiring information.

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

One Pt100 sensor Three Pt100 sensors

Motor

AI1+

AI1-

Motor

AI1+

AI1-

T

T T T

AOx (I)

AGND

AOx (I)

AGND

3.3 nF

> 630 VAC

3.3 nF

> 630 VAC



90

WARNING!

As the inputs pictured above are not insulated according to IEC 60664, the connection of the motor temperature sensor requires double or reinforced insulation between motor live parts and the sensor. If the assembly does not fulfil the requirement,

• the I/O board terminals 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 (XD2D)

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

Termination activation jumper T (see section Jumpers above) next to this terminal block must be set to the ON position on the drives at the ends of the drive-to-drive link. On intermediate drives, the jumper must be set to the OFF position.

Shielded twisted-pair cable (~100 ohm, for example 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 meters (164 ft). Unnecessary loops and running the cable near power cables (such as motor cables) must be avoided. The cable shields must to be grounded to the control cable clamp plate on the drive as shown on page 92 .

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

X5:D2D

Termination ON

JCU

Drive 1

X5:D2D

Termination OFF

JCU

Drive 2

...

X5:D2D

Termination ON

JCU

Drive n



91

Safe torque off (XSTO)

For the drive to start, both connections (OUT1 to IN1, and OUT2 to IN2) must be closed. By default, the terminal block has jumpers to close the circuit. Remove the jumpers before connecting an external Safe Torque Off circuitry to the drive. See page 71 .

Control cable connection procedure

See the cable routing on page 92 and connect the control cables as follows:

1. Ground the shields of all control cables connected to the control unit at the clamp plate. The shields should be continuous as close to the terminals of the control unit as possible. Only remove the outer jacket of the cable at the cable clamp so that the clamp presses on the bare shield.

2. Connect the conductors to the appropriate detachable terminals (see page 87) of the control unit. 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 eg, 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.Tighten the screws to secure the connection.

Note: 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.



92

Routing the control cables

Use shrink tubing or tape to contain strands

Run cables through the cover mounting bracket

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

1.5 N·m (13 lbf·in)



93

Connecting a PC

Connect the PC to terminal X7 on the control unit.

Installing optional modules


Optional modules such as a fieldbus adapters, an I/O extensions and the pulse encoder interfaces are inserted in the optional module slot on the control unit. See page 30 for the available slots.

• Remove the cover assembly (if present) from on the control unit (refer to page

83 ).

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

• Insert the module carefully into its position on the control unit.

• Fasten the screw.

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

Wiring the modules

See the appropriate optional module manual for specific installation and wiring instructions. See page 92 for routing the cables.



94



95

Installation checklist


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

Go through the checklists below together with another person. Follow the Safety instructions on the first pages.


1

1.1

1.2

1.3

1.4

1.5

1.6

Cabinet construction

Checks for cabinet construction are listed below.

Cabinet construction

Frame, wall, floor and roof structures, busbar enclosures and cable entries are correct and completely assembled.

The drive module is fastened properly to the cabinet. (See Planning the cabinet installation and

Mechanical installation.

)

Mechanical joints are tightened and not broken.

Parts are clean and painted surfaces not scratched.

The cabinet frame and parts which are in metal to metal contact with the frame (for example seams, component fixing points on assembly plates, back of control unit mounting plate) are not finished with non-conducting paint or material.

Degree of protection (IPxx)

There is a sufficient number of supports, bolts and nuts for cables.

2

2.1

2.2

2.3

2.4

Instrumentation, busbars and cabling

Checks for instrumentation, busbars, cabling, clearances and creepage distances are listed below. For more information, see chapter Planning the electrical installation .

Instrumentation

Type and number of option modules and other equipment is correct. Option modules and other equipment are not damaged.

Option modules and terminals are labelled correctly.

The placement of option modules and other equipment inside the cabinet and on the cabinet door is correct.

The mounting of option modules and other equipment is correct.

Installation checklist


96

4.3

4.4

4.5

3

3.1

3.2

3.3

3.4

3.5

3.6

4

4.1

4.2

4.6

4.7

4.8

Busbars

The types (Al/Cu) and cross-sections of busbars are correct.

Busbars are intact and joint surfaces are clean. There are no metal scraps on the busbars that could cause a short-circuit.

The placement and mounting of busbars is correct.

The electrical connection of busbars.

Check that the surfaces in electrical connections of aluminium and uncoated busbars are rubbed. Check that anti-oxidant joint compound is used in electrical connections of aluminium busbars. Check that the number of washers and the sizes of bolts are correct.

Busbar supports and lead-in insulators are visually intact and degreased, and placed and mounted correctly.

The electrical connections on the main circuit are tightened to required torque and marked with a green marking.

Cabling and wiring

Wiring of the main circuit. Check

• AC supply input

• AC output

• supply for brake resistor (if used).

Wiring of the drive module control circuit. Check

• JCU Control Unit connections

• control cable connections

• control panel cable connections.

Cable types, cross-sections, colours and optional markings are correct.

Check the cabling for circuits susceptible to interference. Check the twisting of cables and cable routes.

Check that cables without short-circuit protection

• can carry the load current

• are shorter than 3 m (10 ft)

• are assembled separate to other cables

• are protected by an enclosure or duct.

Connection of cables to devices and terminal blocks. Check that

• cables are connected to terminals tight enough by pulling the cable

• cable termination on terminals chaining is done correctly

• bare conductors are not too far outside the terminal causing an insufficient clearance or loss of shielding against contact.

Cables are not lying against sharp edges or bare live parts. Bending radius of fiber optic cables at least

3.5 cm (1.38 in.).

The type, markings, insulation plates and cross connections of terminal blocks are correct.



97

6

6.1

6.2

6.3

6.4

6.5

Groundings and protection

Checks for groundings and protections are listed below. Tips for installations where

EMC emissions must be minimised are given in column Extra requirements for EMC.

Groundings and protection

The grounding colours, cross-section and grounding points of modules and other equipment match the circuit diagrams.

Connections of PE cables and busbars are tight enough.

Pull the cable to test that it does not loosen.

Extra requirements for EMC

No long routes for pigtails

No long routes for pigtails

Doors equipped with electrical equipment are grounded.

No long grounding routes. From EMC standpoint best result is achieved with a flat copper braid.

Fans that can be touched are shrouded.

Live parts inside the doors are protected against direct contact to at least IP 2x (if required).

7

7.1

8.

8.1

Labels, switches, fuses and doors

Checks for labels, switches, fuses and doors are listed below.

Labels

The type designation labels and warning and instruction stickers are made according to the local regulations and placed correctly.

Switches and doors

Check the functioning of mechanical switches, main dicsonnecting switch and cabinet doors.


Checks for electrical installation are listed below. See Planning the electrical installation, Electrical installation.

Check

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

The drive is grounded properly: 1) proper and properly tightenened PE connector, 2) proper galvanic connection between drive frame and cabinet (fastening points are unpainted).

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

The supply (input power) is connected to U1/V1/W1 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 brake 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.

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.



98

Cooling and driven equipment

Checks for cooling conditions and motor and driven equipment before start-up are listed below.

The ambient operating conditions are allowable. (See Technical data : Rating tables, Ambient conditions .)

The cooling air will flow freely. The protective covering is removed from the top of the drive module.

The motor and the driven equipment are ready for start. (See Planning the electrical installation, Technical data :

Motor connection data .)



Start-up


This chapter describes the start-up procedure of the drive.

Start-up procedure

Set-up of the drive program according to the start-up instructions given in the drive firmware manual.

Perform the start-up tasks instructed by the cabinet-installer of the drive module.

99


Start-up

100

Start-up


101

Fault tracing


This chapter describes the fault tracing possibilities of the drive.

LEDs

This table describes LEDs of the drive module.

Where

JINT board

LED

V204 (green)

V309 (red)

V310 (green)

When the LED is lit

+5 V voltage of the board is OK.

Not in use.

IGBT control signal transmission to the gate driver control boards is enabled.

Warning and fault messages

See the Firmware Manual for the descriptions, causes and remedies of the control program warning and fault messages.

Fault tracing


102

Fault tracing


103

Maintenance


This chapter contains preventive maintenance instructions.

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 when stored

Every 6 to 12 months

(depending on the dustiness of the environment)

Every 3 years

Capacitor reforming

Checking the cleanliness of the cabinet and the surroundings

Checking the condition of fiber optic cables

See Reforming the capacitors .

See Cabinet, Heatsink .

See the fault logger. If PPCC

LINK faults have recurred, change the fiber optic cables.

See Fan .

Every 3 years if the ambient temperature is higher than

40 °C (104 °F).

Otherwise, every 6 years .

Every 6 years if the ambient temperature is higher than

40 °C (104 °F) or if the drive is subjected to cyclic heavy load or continuous nominal load.

Otherwise, every 9 years .

Every 9 years

Cooling fan change

Capacitor change See Capacitors .

Every 10 years

JINT board and flat cable change

Control panel battery replacement.

Contact ABB.

The battery is housed on the rear of the control panel.

Replace with a new CR 2032 battery.

Consult your local ABB Service representative for more details on the maintenance.

On the Internet, go to ABB website and select Drive Services –

Maintenance and Field Services .

Cabinet

When necessary, clean the interior of the cabinet with a soft brush and a vacuum cleaner.

Maintenance


104

Heatsink

The module heatsink fins pick up dust from the cooling air. The drive runs into overtemperature warnings and faults if the heatsink is not clean. When necessary, contact ABB for cleaning of the heatsink.

Fan

The lifespan of the cooling fan of the drive module is about 50 000 hours. The actual lifespan depends on the running time of the fan, ambient temperature and dust concentration. See the appropriate Firmware Manual for the actual signal which indicates the running time of the cooling fan. For resetting the running time signal after a fan replacement, please contact ABB.

Replacement fans are available from ABB. Do not use other than ABB specified spare parts.

Maintenance


105

Replacing the cooling fan of the module

WARNING! Folow the safety instructions, page 14 . Ignoring the instructions can cause physical injury or death, or damage to the equipment

1. Remove the front cover.

2. Disconnect the fan capacitor and power supply wires.

3. Undo the red fastening screws of the plastic side cover of the fan. Shift the cover to the right to free its right-hand edge and lift the cover off.

4. Undo the red fastening screws of the fan.

5. Lift the fan out of the cabinet.

6. Install the new fan and fan capacitor in reverse order to the above.

1

1

2

2

3

4

4

5

3

3

M5×8, 2 N·m (1.5 lbf·ft) M6, 8 N·m (6 lbf·ft)

Maintenance


106

Replacing the drive module

The drive module can be replaced by disconnecting the pedestal and busbars connected to it from the drive module and leaving the pedestal and busbars into the cabinet. Proceed as follows:

WARNING! Follow the safety instructions, page 14 . Ignoring the instructions can cause physical injury or death, or damage to the equipment

1. Disconnect the input power cable from the module.

2. Disconnect the power supply cable and the fibre optic cables from the JCU

Control Unit and coil them on the top of the drive module.

3. Undo the upper fastening screws of the module (if used).

4. Undo the screws (2 pcs) that fasten the outer support bracket to the drive module.

5. Remove the front cover, see page 105 .

6. Undo the pedestal fastening screws.

7. Undo the screws that fasten the internal busbars of the pedestal to the drive module busbars.

8. Secure the module from the lifting hooks at the top.

9. Pull the module from the cabinet onto a pallet truck.

10.Install the new module in reverse order to the above.

1

3

M6, 8 N·m (6 lbf·ft)

4

4

4

Maintenance


107

5

6

6 6

7

7

7

7

6

6 6

8

9

6 M6×16 combi, 8 N·m (6 lbf·ft)

7 M10×25 combi, 30 N·m (22 lbf·ft)

Pedestal when the module is removed

Note: A drive module trolley is available from ABB. The trolley helps in removing heavy drive modules from a cabinet and in replacing the module.

Maintenance


108

Capacitors

The drive intermediate circuit employs several electrolytic capacitors. Their lifespan is at least 90 000 hours depending on the operating time of the drive, loading and ambient temperature. Capacitor life can be prolonged by lowering the ambient temperature.

It is not possible to predict a capacitor failure. Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. Contact ABB if capacitor failure is suspected. Replacements are available from ABB. Do not use other than ABB specified spare parts.

Reforming the capacitors

The capacitors must be reformed if the drive has been stored for a year or more. See page 32 for information on finding out the manufacturing date. For information on reforming the capacitors, contact your local ABB representative.

Maintenance


109

Replacing the capacitor pack

WARNING! Follow the safety instructions, page 14 . Ignoring the instructions can cause physical injury or death, or damage to the equipment

1. Remove the front cover, see (1) on page 105 . Remove the profiled side plate.

2. Disconnect the discharging resistor wires. The upper ones are connected with the same nut as the busbar.

3. Undo the fastening screws (detail photos A, B, C, D).

4. Lift the capacitor pack out.

5. Install the new capacitor pack in reverse order to the above.

1

3

A

3

1

C

D

B

2 3 2 3

3

A

3

2*

3 M6, 8 N·m (6 lbf·ft) 2* M6, 5 N·m ( 4 lbf·ft)

3

3

B

Maintenance


110

C 3

3 M10

3 3 D M6×12 combi screw

M6×12 combi, 8 N·m (6 lbf·ft)

M10, 30 N·m (22 lbf·ft)

4

Capacitor pack removed

Memory unit

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. The memory unit is located in the JCU Control Unit, see page 27 .

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.

Maintenance


111

Technical data


This chapter contains the technical specifications of the drive, for example, the ratings, sizes and technical requirements, provisions for fulfilling the requirements for

CE and other markings.

Ratings

The nominal ratings for the drive modules with 400 V (50 Hz and 60 Hz) supply are given below. The symbols are described below the table.

Drive type

ACS850-04…

Frame size

Input ratings

-430A-5

-521A-5

-602A-5

-693A-5

-720A-5

G

G

G

G

G

I

1N

A

423

501

581

674

705

Nominal

I

2N

A

430

521

602

I

Max

A

588

588

840

No-overload use kW

200

250

315

693 1017 355

720 1017 400

P

N

* hp

350

450

500

500

600

Output ratings

Light-overload use

I

Ld

A

425

516

590

679

704 kW

P

Ld

* hp

200

250

315

355

400

350

450

500

500

600

Heavy-duty use

I

Hd

A

340

370

477

590

1)

6352) kW

P

Hd

* hp

160

200

250

315

355

250

300

400

500

500

00581898

I

1N

I

2N

I

Max

P

N

I

Ld

Nominal input current (rms) at 40 °C (104 °F)

Nominal output current

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

Typical motor power in no-overload use.

Continuous rms output current. 10% overload is allowed for 1 minute every 5 minutes.

P

Ld

I

Hd

Typical motor power for light-overload use.

Continuous rms output current. 50% overload is allowed for 1 minute every 5 minutes.

P

Hd

Typical motor power for heavy-duty use.

* The typical motor powers for 500 V supply are higher (maximum power 500 kW).

Note: 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.

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.

Technical data


112

Ambient temperature derating

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

Derating factor

1.00

0.85

+40 °C

+104 °F

+55 °C

+131 °F

Ambient temperature

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.

Fuses (IEC)

gG and aR fuses for protection against short-circuit in the input power cable or drive are listed below. Either fuse type may be used if it operates rapidly enough. Choose between gG and aR fuses according to the table under Quick guide for selecting between gG and aR fuses on page 115, or verify the operating time by checking that the short-circuit current of the installation is at least the value given in the fuse table . The short-circuit current can be calculated as follows:

U

I k2-ph

=

2 · R c

2 + ( Z k

+ X c

) 2 where

I k2-ph

= short-circuit current in symmetrical two-phase short-circuit (A)

U = network line-to-line voltage (V)

R c

= cable resistance (ohm)

Z k

= z k

· U

N

2 / S

N

= transformer impedance (ohm) z k

= transformer impedance (%)

U

N

= transformer rated voltage (V)

S

N

= nominal apparent power of the transformer (kVA)

X c

= cable reactance (ohm).

Technical data


113

Calculation example

Drive:

• ACS850-04-430A-5

• supply voltage U = 410 V

Transformer:

• rated power S

N

= 3000 kVA

• rated voltage U

N

= 430 V

• transformer impedance z k

= 7.2%.

Supply cable:

• length = 170 m

• resistance/length = 0.112 ohm/km

• reactance/length = 0.0273 ohm/km.

Z k

= z k

·

U

N

2

S

N

= 0.072

·

(430 V)

2

3000 kVA

= 4.438 mohm

R c

= 170 m · 0.112

ohm km

= 19.04 mohm

X c

= 170 m · 0.0273

ohm km

= 4.641 mohm

I k2-ph

=

2 ·

410 V

(19.04 mohm) 2 + (4.438 mohm + 4.641 mohm) 2

= 9.7 kA

The calculated short-circuit current 9.7 kA is higher than the minimum short-circuit current of the drive gG fuse type OFAF3H500 (8280 A). -> The 500 V gG fuse (ABB Control OFAF3H500) can be used.

Technical data


114

Fuse tables

Drive type

ACS850-04…

-430A-5

-521A-5

-602A-5

-693A-5

-720A-5 gG fuses

Input current

A

423

501

Min. shortcircuit current 1)

A

8280

10200

A

500

630

A

2 s

2 900 000

4 000 000

581

674

10200

13500

630

800

4 000 000

7 400 000

705 13500 800 7 400 000

1)

minimum short-circuit current of the installation

V

500

500

500

500

500

Fuse

Manufacturer

ABB Control

ABB Control

ABB Control

ABB Control

ABB Control

Type

OFAF3H500

OFAF3H630

OFAF3H630

OFAF3H800

OFAF3H800

IEC size

3

3

3

3

3

Note 1: See also Implementing thermal overload and short-circuit protection on page 69 . For UL recognized fuses, see Fuses (UL) on page 115 .

Note 2: In multicable installations, install only one fuse per phase (not one fuse per conductor).

Note 3: Larger fuses than the recommended ones must not be used.

Note 4: Fuses from other manufacturers can be used if they meet the ratings and the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table.

00581898, 00556489 A

Ultrarapid (aR) fuses

Drive type

ACS800-04…

Input current

A

Min. shortcircuit current

1)

A A A 2 s V

Fuse

Manufacturer Type DIN 43620 Size

-430A-5

-521A-5

-602A-5

-693A-5

-720A-5

423

501

581

4000

7800

7800

800

1250

1250

465 000

1 950 000

1 950 000

690

690

690

Bussmann

Bussmann

Bussmann

170M6812

170M8554

170M8554

674 8850 1400 3 900 000

705 8850 1400 3 900 000

1)

minimum short-circuit current of the installation

690

690

Bussmann

Bussmann

170M8555

170M8555

Note 1: See also Implementing thermal overload and short-circuit protection on page 69 . For UL recognized fuses, see Fuses (UL) on page 115 .


DIN2*

DIN3

DIN3

DIN3

DIN3



00581898, 00556489 A

Technical data


115

Drive type

ACS850-04…

-430A-5

-521A-5

-602A-5

-693A-5

-720A-5

Quick guide for selecting between gG and aR fuses

The table below is a short cut in selecting between gG and aR fuses. The combinations (cable size, cable length, transformer size and fuse type) in the table fulfill the minimum requirements for the proper operation of the fuse.

Cable type

Copper

Supply transformer minimum apparent power S

N

(kVA)

Aluminum Maximum cable length with gG fuses

Maximum cable length with aR fuses

10 m

2 x (3x120) Cu 3 x (3x95) Al 530

3 x (3x95) Cu 3 x (3x150) Al 660

50 m

570

720

100 m

670

840

10 m

370

500

100 m

370

570

200 m

370

760

3 x (3x120) Cu 3 x (3x185) Al 660

2 x (3x240) Cu 3 x (3x240) Al 880

720

980

840

1200

520

580

570

670

760

880

3 x (3x150) Cu 3 x (3x240) Al 880 980 1200 610 670 880

Note 1: The supply transformer minimum power in kVA is calculated with a z k frequency 50 Hz.

value of 6% and

Note 2: The table is not intended for transformer selection - that must be done separately.

00556489 A

The following parameters can affect the correct operation of the protection:

• cable length ie, the longer the cable the weaker the fuse protection, as the long cable limits the fault current

• cable size ie, the smaller the cable cross-section the weaker the fuse protection, as the small cable size limits the fault current

• transformer size ie, the smaller the transformer the weaker the fuse protection, as the small transformer limits the fault current

• transformer impedance ie, the higher the z k high impedance limits the fault current.

the weaker the fuse protection as

The protection can be improved by installing a larger supply transformer and/or bigger cables, and in most cases by selecting aR fuses instead of gG fuses.

Selection of smaller fuses improves the protection, but may also affect the fuse life time and lead to unnecessary operation of the fuses.

In case of any uncertainty regarding the drive protection, please contact your local

ABB representative.

Fuses (UL)

UL class T or L fuses for branch circuit protection per NEC are listed below. Fast acting class T or faster fuses are recommended in the USA.

Check from the fuse time-current curve that the operating time of the fuse is below 0.1 seconds . The operating time depends on the supply network impedance and the cross-sectional area and length of the supply cable. The short-circuit current can be calculated as shown on page 112 .

Technical data


116

UL class T and L fuses

Drive type

ACS850-04…

-430A-5

-521A-5

-602A-5

-693A-5

-720A-5

Input current

A

423

501

581

674

A

500

600

800

800

V

600

600

600

600

Fuse

Manufacturer

Bussmann

Bussmann

Ferraz

Ferraz

Type

JJS-500

JJS-600

A4BY800

UL class

T

T

L

A4BY800 L

705 800 600 Ferraz A4BY800 L

Note 1: See also Implementing thermal overload and short-circuit protection on page

69 .




00581898

Dimensions, weights and free space requirements

H mm

Busbars on the long side

(bookshelf)

W1 mm

W2 mm

D mm

1564 415 562 568

IP00

Busbars on the short side (flat)

H mm

1596

W3 mm

607

W4 mm

779

D mm

403

Weight kg

200

Height in.

61.57

UL type open

W1 in.

16.35

W2 in.

22.14

Depth in.

22.36

Weight lb

441

H height

W1 width of the basic unit with PE terminal (bookshelf)

W2 width with the cable connection terminal plates on the left side only (bookshelf)

(width with the cable connection terminal plates on both sides is 776 mm)

D depth without fastening brackets

(bookshelf mounting: depth with fastening brackets is 571 mm)

W3 width of the basic unit with PE terminal/busbar (flat)

W4 width with the cable connection terminal plates (flat)

For requirements of free space around the drive module, see 43 .

Technical data


117

Losses, cooling data and noise

Drive type

ACS850-04…

-430A-5

-521A-5

-602A-5

-693A-5

-720A-5

Frame size

R8

R8

R8

R8

R8 m

3

/h

Air flow ft

3

/min

1220

1220

1220

1220

1220

718

718

718

718

718

Heat dissipation

W BTU/Hr

6850

7800

7600

8100

9100

22550

24420

27670

29550

31080

Noise dB

72

72

72

72

72

IP22 cabinet with no extra fan

An IP22 cabinet should meet the following data to ensure efficient cooling of the drive module. No extra fan is used. The pressure drop over the cabinet is the additional counterpressure that the module fan is capable of overcoming while still maintaining the required air flow through the module.

Temperature rise over module

Pressure drop

Cabinet air inlet

Cabinet air outlet size

30 °C

300 Pa (over module), 45 Pa over cabinet

Minimum size (mm): 288×292+688×521

Filter by Luftfilter: airTex G150

398 mm × 312 mm (2 pcs) when the outlet is located on the cabinet roof

00096931

IP54 cabinet with an extra fan

An IP54 cabinet should meet the following data to ensure efficient cooling of the drive module. An extra fan is used. The pressure drop over the cabinet is the counterpressure the extra fan must overcome. The given fan types and filter materials are examples. Corresponding products by another manufacturer may be used as well. See the manufacturer’s Internet site for the detailed specification.

Temperature rise over module

Pressure drop

30 °C

250 Pa (over cabinet), average, air filters moderately congested

Extra fan type RH35M-4EK.2F.1R by Ziehl-Abegg or RB4T-355/170 by ebm

Air inlet filter by Luftfilter airComp 300-50,

Minimum size in door (mm): 288×292 + 688×521

Air outlet filter by

Luftfilter airTex G150

Minimum size at roof (mm): 398×312 (2 pcs)

00096931

Technical data


118

Terminal and lead-through data for the power cables

Input, motor and brake resistor cable terminal sizes (per phase), maximum accepted cable and tightening torques are given below.

U1, V1, W1, U2, V2, W2, UDC+/R+, UDC-, R-

Number of holes per phase

Max. cable Screw Tightening torque mm

2

N·m

3 3×240 M12 50...75

Grounding PE

Screw

M10

Tightening torque

N·m

30...44

Max. cable kcmil/AWG

3 × 700 MCM

U1, V1, W1, U2, V2, W2, UDC+/R+, UDC-, R- Grounding PE

Screw Tightening torque Screw Tightening torque

1/2 lbf·ft

37...55

3/8 lbf·ft

22...32

Two-hole 1/2 inch diameter cable lugs can be used.

Terminal data for the control cables

See page 87 .

Electrical power network specification

Voltage ( U

1

)

Rated conditional shortcircuit current (IEC 60439-1)

Short-circuit current protection (UL 508C,

CSA C22.2 No. 14-05)

Frequency

Imbalance

Fundamental power factor

(cos phi

1

)

380/400/415/440/460/480/500 VAC 3-phase ± 10%

65 kA when protected by fuses given in the fuse tables

US and Canada: The drive is suitable for use on a circuit capable of delivering not more than 100 kA symmetrical amperes (rms) at 600 V maximum when protected by fuses given in the table Fuses (UL) .

48 to 63 Hz, maximum rate of change 17%/s

Max.

± 3% of nominal phase to phase input voltage

0.98 (at nominal load)

Motor connection data

Motor types

Voltage ( U

2

)

Frequency

Asynchronous AC induction motors, permanent magnet synchronous motors

0 to U

1

, 3-phase symmetrical, U max

at the field weakening point

DTC mode: 0 to 3.2 · f f

. Maximum frequency 500 Hz (120 Hz with du/dt or sine filter). Low motor noise mode is recommended with high frequencies (see also Firmware manual ). f f

=

U

N

U m

· f m

Frequency resolution

Current

Field weakening point

Switching frequency f f

: frequency at field weakening point; U

N motor voltage; f m

: rated motor frequency

: electrical power system voltage; U m

: rated

0.01 Hz

See section Ratings.

0…500 Hz

3 kHz (typically)

Technical data


119

Maximum recommended motor cable length

Type code (EMC equipment)

-

+E210 *

DTC control

300 m (984 ft)

100 m (328 ft)

Max. motor cable length

Scalar control

300 m (984 ft)

100 m (328 ft)

* Motor cable longer than 100 m (328 ft) is allowed but then the EMC Directive requirements may not be fulfilled.

Brake resistor connection data

See page 142 .

Control unit (JCU-11) connection data

Power supply

Relay outputs RO1…RO3

(XRO1 … XRO3)

24 V (±10%) DC, 1.6 A

Supplied from the power unit of the drive, or from an external power supply through connector XPOW (pitch 5 mm, wire size 2.5 mm 2 ).

Connector pitch 5 mm, wire size 2.5 mm

2

250 V AC / 30 V DC, 2 A

Protected by varistors

Note: The relay outputs of the drive do not fulfill the Protective Extra Low Voltage (PELV) requirements at installation sites above 4000 meters (13123 feet) if used with a voltage greater than 48 V. At installation sites between 2000 meters (6562 feet) and 4000 meters

(13123 feet), PELV requirements are not fulfilled if one or two relay outputs are used with a voltage greater than 48 V and the remaining relay output(s) are used with a voltage lower than 48 V.

Connector pitch 5 mm, wire size 2.5 mm 2 +24 V output

(XD24)

Digital inputs DI1…DI6

(XDI:1 … XDI:6)

Connector pitch 3.5 mm, wire size 1.5 mm

2

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

R in

: 2.0 kohm

Filtering: 0.25 ms min.

Start interlock input DIIL

(XDI:A)

DI6 (XDI:6) can alternatively be used as an input for 1…3 PTC thermistors. Note: The input has no safety insulation (see page 90 ).

I max

: 15 mA

Wire size 1.5 mm

2

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

R in

: 2.0 kohm

Technical data


120

Digital inputs/outputs DIO1 and DIO2

(XDIO:1 and XDIO:2)

Input/output mode selection by parameters.

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

DIO2 can be configured as a

24 V level square wave frequency output. See

Firmware Manual, parameter group 12.


2

As inputs:

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

R in

: 2.0 kohm


As outputs:

Total output current limited by auxiliary voltage outputs to 200 mA

Output type: Open emitter

V

CC

DIOx

R

L

DGND

Reference voltage for analog inputs +VREF and -VREF

(XAI:1 and XAI:2)

Analog inputs AI1 and AI2

(XAI:4 … XAI:7).

Current/voltage input mode selection by jumpers. See page 88 .

Analog outputs AO1 and

AO2

(XAO)

Drive to drive link

(XD2D)

Safe Torque Off connection

(XSTO)

Control panel / PC connection


2

10 V ±1% and –10 V ±1%, R load

> 1 kohm


Current input: –20…20 mA, R in:

Voltage input: –10…10 V, R

100 ohm in

: 200 kohm

Differential inputs, common mode ±20 V

Sampling interval per channel: 0.25 ms


Resolution: 11 bit + sign bit

Inaccuracy: 1% of full scale range


2

0…20 mA, R load

< 500 ohm

Frequency range: 0…800 Hz

Resolution: 11 bit + sign bit

Inaccuracy: 2% of full scale range


2

Physical layer: RS-485

Termination by jumper


2

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

Connector: RJ-45

Cable length < 3 m

2

Technical data


Isolation and grounding diagram

XPOW

1

2

+24VI

GND

7

8

5

6

9

3

4

1

2

XRO1…XRO3

NO

COM

NC

NO

COM

NC

NO

COM

NC

5

6

3

4

7

XAI

1

2

3

4

XAO

1

2

3

4

XD24

1

2

+24VD

DIGND

+24VD

DIOGND

6

A

4

5

2

3

XDI

1

XDIO

1

2

DI1

DI2

DI3

DI4

DI5

DI6

DIIL

DIO1

DIO2

+VREF

-VREF

AGND

AI1+

AI1-

AI2+

AI2-

AO1+

AO1-

AO2+

AO2-

XD2D

1

2

3

3

4

XSTO

1

2

B

A

BGND

OUT1

OUT2

IN1

IN2

Common mode voltage between channels

± 20 V

Ground

Efficiency

Approximately 98% at nominal power level

Degree of protection

IP00 (UL type open)

121

Technical data


122

Ambient conditions

Installation site altitude

Air temperature

Relative humidity

Contamination levels

(IEC 60721-3-3, IEC 60721-3-

2, IEC 60721-3-1)

Atmospheric pressure

Vibration (IEC 60068-2)

Shock (IEC 60068-2-29)

Free fall

Environmental limits for the drive are given below. The drive is to be used in a heated, indoor, controlled environment.

Operation

installed for stationary use

0 to 4000 m (13123 ft) above sea level (above 1000 m

[3281 ft]), see section

Derating ]

-15 to +55 °C (5 to 131 °F).

No frost allowed. See section Derating .

-

Storage in the protective package

-40 to +70 °C (-40 to

+158 °F)

-

Transportation in the protective package

-40 to +70 °C (-40 to

+158 °F)

5 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.

Boards with coating:

Chemical gases: Class 3C2

Solid particles: Class 3S2







70 to 106 kPa

0.7 to 1.05 atmospheres

Max. 1 mm (0.04 in.)

(5 to 13.2 Hz), max. 7 m/s 2 (23 ft/s 2 )

(13.2 to 100 Hz) sinusoidal

Not allowed

Not allowed

70 to 106 kPa


Max. 1 mm (0.04 in.)

(5 to 13.2 Hz), max. 7 m/s 2 (23 ft/s 2 )

(13.2 to 100 Hz) sinusoidal

Max. 100 m/s 2 (330 ft./s 2 ),

11 ms

100 mm (4 in.) for weight over 100 kg (220 lb)

60 to 106 kPa


Max. 3.5 mm (0.14 in.)

(2 to 9 Hz), max. 15 m/s 2 (49 ft/s 2 )

(9 to 200 Hz) sinusoidal

Max. 100 m/s 2 (330 ft./s 2 ),

11 ms

100 mm (4 in.) for weight over 100 kg (220 lb)

Technical data


123

Materials

Drive enclosure

Package

Disposal

• PC/ABS 2.5 mm, colour NCS 1502-Y (RAL 90021 / PMS 420 C)

• hot-dip zinc coated steel sheet 1.5 to 2.5 mm, thickness of coating 100 micrometers, colour NCS 1502-Y

Plywood and cardboard. Foam cushions PP-E, bands PP.

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 (C1-1 to C1-x) contain electrolyte and the printed circuit boards contain lead, both of which are classified as hazardous waste within the EU. They must be removed and handled according to local regulations.

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

Applicable standards

EN 61800-5-1:2003

EN 60204-1:2006

EN 60529:1992 (IEC 60529) Degrees of protection provided by enclosures (IP code)

IEC 60664-1:2007 Insulation coordination for equipment within low-voltage systems. Part 1: Principles, requirements and tests.

EN 61800-3:2004 Adjustable speed electrical power drive systems. Part 3: EMC requirements and specific test methods

EN 61800-5-2:2007

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

Voltage Directive is verified according to standards EN 61800-5-1 and EN 60204-1.

Adjustable speed electrical power drive systems. Part 5-1: Safety requirements – electrical, thermal and energy

Safety of machinery. Electrical equipment of machines. Part 1: General requirements.

Provisions for compliance: The final assembler of the machine is responsible for installing

- emergency-stop device

- supply disconnecting device

- drive module into a cabinet.

UL 508C (2002)

CSA C22.2 No. 14-05

Adjustable speed electrical power drive systems. Part 5-2: Safety requirements –

Functional

UL Standard for Safety, Power Conversion Equipment, second edition

Industrial control equipment

Technical data


124

CE marking

A CE mark is attached to the drive to verify that the unit follows the provisions of the European Low

Voltage and EMC Directives.

Compliance with the European Low Voltage Directive

The compliance with the European Low Voltage Directive has been verified according to standards

EN 61800-5-1 and EN 60204-1.

Compliance with the European EMC Directive

The EMC Directive defines the requirements for immunity and emissions of electrical equipment used within the European Union. The EMC product standard (EN 61800-3:2004) covers requirements stated for drives. See section Compliance with the EN 61800-3:2004 below.

Compliance with the European Machinery Directive

The drive complies with the European Union Machinery Directive (98/37/EC) requirements for an equipment intended to be incorporated into machinery.

“C-tick” marking

“C-tick” marking is required in Australia and New Zealand. A “C-tick” mark is attached to each drive in order to verify compliance with the relevant standard (IEC 61800-3:2004, Adjustable speed electrical power drive systems – Part 3: EMC product standard including specific test methods ), mandated by the

Trans-Tasman Electromagnetic Compatibility Scheme.

For fulfilling the requirements of the standard, see section Compliance with the EN 61800-3:2004 below.

Compliance with the EN 61800-3:2004

Definitions

EMC stands for E lectro m agnetic C ompatibility. 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 establishments connected to a low-voltage network which supplies buildings used for domestic purposes.

Second environment includes establishments connected to a network not supplying domestic premises.

Drive of category C2: drive of rated voltage less than 1000 V and intended to be installed and commissioned only by a professional when used in the first environment. Note: A professional is a person or organisation having necessary skills in installing and/or commissioning power drive systems, including their EMC aspects.

Drive of category C3: drive of rated voltage less than 1000 V and intended for use in the second environment and not intended for use in the first environment.

Drive of category C4: drive of rated voltage equal to or above 1000 V, or rated current equal to or above

400 A, or intended for use in complex systems in the second environment.

Technical data


125

Category C3

The drive complies with the standard with the following provisions:

1. The drive is equipped with EMC filter +E210. The filter is suitable for TN (earthed) and IT

(unearthed) systems.

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

3. The drive is installed according to the instructions given in the Hardware Manual .

4. Maximum cable length is 100 metres.

WARNING!

A drive of category C3 is not intended to be used on a low-voltage public network which supplies domestic premises. Radio frequency interference is expected if the drive is used on such a network.

Category C4

If the provisions under Category C3 cannot be met, the requirements of the standard can be met as follows:

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

Medium voltage network

Supply transformer

Neighbouring network

Static screen

Low voltage

Point of measurement

Equipment

(victim)

Equipment

Low voltage

Equipment

Drive

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 Hardware Manual .

4. The drive is installed according to the instructions given in the Hardware Manual .

WARNING!

A drive of category C4 is not intended to be used on a low-voltage public network which supplies domestic premises. Radio frequency interference is expected if the drive is used on such a network.

Technical data


126

UL marking

The drive module is C-UL US Listed. The approval is valid with rated voltages.

UL checklist

The drive is suitable for use on a circuit capable of delivering not more than 100 kA rms symmetrical amperes at the drive nominal voltage when protected by fuses given in the Fuses (UL) fuse table. The ampere rating is based on tests done according to UL 508C.

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

Firmware Manual for setting. Default setting is off, must be activated at start-up.

The drives are to be used in a heated indoor controlled environment. See section Ambient conditions for specific limits.

Brake chopper - ABB has brake choppers that, when applied with appropriately sized brake resistors, will allow the drive to dissipate regenerative energy (normally associated with quickly decelerating a motor). Proper application of the brake chopper is defined in chapter Resistor braking .

CSA marking

The drive module is CSA marked. The approval is valid with rated voltages.

Patent protection in the USA

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

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

Other patens pending.

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

7,250,739 7,262,577

7,330,095 7,349,814

7,388,765 D503,931

D512,026

D510,319

D512,696 D521,466

D548,182S D548,183S

5,521,483

5,940,286

6,184,740

6,313,599

6,498,452

5,532,568

5,942,874

6,195,274

6,316,896

6,552,510

5,589,754

5,952,613

6,229,356

6,335,607

6,597,148

6,844,794

6,956,352

6,985,371

7,045,987

7,098,623

7,215,099

7,271,505

7,352,220

6,856,502

6,958,923

6,992,908

7,057,908

7,102,325

7,221,152

7,274,573

7,365,622

6,859,374

6,967,453

6,999,329

7,059,390

7,109,780

7,227,325

7,279,802

7,372,696

D510,320 D511,137 D511,150

D541,743S D541,744S D541,745S

Technical data


127

Dimension drawings


This chapter contains dimension drawings of the drive modules as well as auxiliary components.

Frame size G without pedestal (mm)

Center of gravity

64801082_3/6 E

Dimension drawings


128

Frame size G with busbars on the left side (mm)



Frame size G pedestal busbars on the long side (mm)

129

Bilateral output busbar

64801082_4/6 E



130

Drive control unit (JCU)



Package

131



132

Dimension drawings (USA)

Frame size G without pedestal (inches)

Center of gravity

68440513_3/6 A (64801082.asm E)



Frame size G with busbars on the left side (inches)

133



134

Frame size G pedestal busbars on the long side (inches)

Bilateral output busbar

68440513_4/6 A (64801082.asm E)



135

Example circuit diagrams


This chapter shows an example circuit diagram for a cabinet-installed drive module.

Example circuit diagrams


136

Example circuit diagram

This diagram is an example for the main wiring of a drive cabinet. Note that the diagram includes components which are not included in a basic delivery (* plus code options, ** other options, *** to be acquired by the customer).

*Common mode filter

Example circuit diagrams


137

Resistor braking


This chapter describes how to select, protect and wire brake resistors.

Availability of brake choppers and resistors

Brake choppers are optionally available as built-in units, indicated in the type description by +D150.

Resistors are available as add-on kits.

When is resistor braking needed

Typically, a drive system is equipped with brake choppers and resistors if:

• high capacity braking is needed and the drive cannot be equipped with a regenerative supply unit

• a backup for the regenerative supply unit is needed.

Operation principle

The energy generated by the motor during a fast deceleration of the drive typically causes the voltage to rise in the drive module intermediate DC circuit. The chopper connects the brake resistor to the intermediate DC circuit whenever the voltage in the circuit exceeds its maximum limit. Energy consumption by the resistor losses lowers the voltage until the resistor can be disconnected.

Hardware description

The resistors available from ABB as add-on kits are built in an IP00 metal frame.

2×SAFUR and 4×SAFUR resistors are connected in parallel.

Planning the braking system

Selecting the brake circuit components

1. Calculate the maximum power (P max

) generated by the motor during braking.

Resistor braking


138

2. Select a suitable drive and brake resistor combination for the application according to the rating table on page 141 . Take also account of other factors in the drive selection. The braking power must be greater than or equal to the maximum power generated by the motor during braking:

P br

> P max where

P br denotes P br5

, P br10

, P br30

, P br60

, or P brcont

depending on the duty cycle.

3. Check the resistor selection. The energy generated by the motor during a 400second period must not exceed the resistor heat dissipation capacity E

R

.

Note: If the E

R

value is not sufficient, it is possible to use a four-resistor assembly in which two standard resistors are connected in parallel, two in series. The E

R value of the four-resistor assembly is four times the value specified for the standard resistor.

A resistor other than the standard resistor can be used provided that:

• its resistance is not lower than the resistance of the standard resistor

WARNING! Never use a brake resistor with a resistance below the value specified for the particular drive / brake chopper / resistor combination. The drive and the chopper are not able to handle the overcurrent caused by the low resistance.

• the resistance does not restrict the braking capacity needed ie,

P max <

U

DC

2

R where

P max

U

DC

R

Maximum power generated by the motor during braking

Voltage over the resistor during braking eg,

1.35 · 1.2 · 415 V DC when supply voltage is 380 to 415 VAC

1.35 · 1.2 · 500 V DC when supply voltage is 440 to 500 VAC

Resistor resistance (ohm)

• the heat dissipation capacity (E

R above.

) is sufficient for the application, see step 3

Placing the brake resistors

All resistors must be installed outside the drive module in a place where they will cool and the maximum allowed cable length (10 m [33 ft]) is not exceeded.

Arrange the cooling of the resistor in a way that:

• no danger of overheating is caused to the resistor or nearby materials

Resistor braking


139

• the temperature of the room the resistor is located in does not exceed the allowed maximum.

Supply the resistor with cooling air/water according to the resistor manufacturer’s instructions.

WARNING! The materials near the brake resistor must be non-flammable. The surface temperature of the resistor is high. Air flowing from the resistor is of hundreds of degrees Celsius. If the exhaust vents are connected to a ventilation system, ensure that the material withstands high temperatures. Protect the resistor against contact.

Protecting the system in fault situations

Thermal overload protection

The brake chopper protects itself and the resistor cables against thermal overload when the cables are dimensioned according to the nominal current of the drive. The drive control program includes a resistor and resistor cable thermal protection function which can be tuned by the user. See the Firmware Manual .

A main contactor is not required for protecting against resistor overheating when the resistor is dimensioned according to the instructions and the internal brake chopper is in use. The drive will disable power flow through the input bridge if the chopper remains conductive in a fault situation. Note: If an external brake chopper (outside the drive module) is used, a main contactor is always required.

A thermal switch (standard in ABB resistors) is required for safety reasons. The cable must be shielded and not longer than the resistor cable.

Thermal switch

(standard in ABB resistors)

Θ

Digital input of the JCU Control Unit.

See the Firmware Manual for parameter settings.

Short-circuit protection

The input fuses will also protect the resistor cable when it is dimensioned according to the input cable.

Selecting and routing the brake circuit cables

Use the cable type used for drive input cabling (refer to chapter Technical data) to ensure that the input fuses will also protect the resistor cable. Alternatively, twoconductor shielded cable with the same cross-sectional area can be used.

Resistor braking


140

Minimizing electromagnetic interference

Follow these rules in order to minimise electromagnetic interference caused by the rapid current changes in the resistor cables:

• Shield the braking power line completely, either by using shielded cable or a metallic enclosure. Unshielded single-core cable can only be used if it is routed inside a cabinet that efficiently suppresses the radiated RFI emissions.

• Install the cables away from other cable routes.

• Avoid long parallel runs with other cables. The minimum parallel cabling separation distance should be 0.3 metres.

• Cross the other cables at right angles.

Cable length

Keep the cable as short as possible in order to minimise the EMC emissions and stress on chopper IGBTs. The longer the cable the higher the EMC emissions, inductive load and voltage peaks over the IGBT semiconductors of the brake chopper.

EMC compliance of the complete installation

Note: ABB has not verified that the EMC requirements are fulfilled with external user-defined brake resistors and cabling. The EMC compliance of the complete installation must be considered by the customer.


See the resistor manufacturer’s instructions.


See the power cable connection diagram of the drive, page 79 .

Brake circuit commissioning

For more information, see the appropriate Firmware Manual .

• Enable the brake chopper function. Please note that a brake 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 brake chopper but the chopper is not enabled by parameter setting, the brake resistor must be disconnected because the protection against resistor overheating is then not in use.

Resistor braking


141

Technical data

Drive type

ACS850-04…

-430A-5

-521A-5

-602A-5

-693A-5

-720A-5

Ratings

The ratings for selecting the brake system components are given below at an ambient temperature of 40 °C (104 °F). Check that the braking energy transmitted to the specified resistor(s) in 400 seconds does not exceed E

R

.

See page 137 .

G

G

G

G

G

Frame size

Braking power (drive + chopper)

5/60 s 10/60 s 30/60 s

P br5

(kW)

300

375

480

600

600 1)

P br10

(kW)

300

375

480

400

2)

400 2)

P br30

(kW)

300

375

470

300

300

P brcont

(kW)

300

234

210

170

170

Brake resistor(s)

Type

2xSAFUR125F500

2XSAFUR210F575

2xSAFUR200F500

4xSAFUR125F500

4xSAFUR125F500

R

(ohm)

2.00

1.7

1.35

1.00

1.00

E

R

(kJ)

7200

8400

10800

14400

14400

P

Rcont

(kW)

18

21

27

36

36

00581898

Definitions

P

1)

2) br5

P br10

P br30

P brcont

R

E

P

R

Rcont

Maximum braking power of the drive with the specified resistor(s). The drive and the chopper will withstand this braking power for 5 seconds per minute.

The drive and the chopper will withstand this braking power for 10 seconds per minute.

The drive and the chopper will withstand this braking power for 30 seconds per minute.

The drive and the chopper will withstand this continuous braking power. The braking is considered continuous if the braking time exceeds 30 s.

Resistance value for the resistor assembly. Note: This is also the minimum allowed resistance for the brake resistor.

Short energy pulse that the resistor assembly withstands every 400 seconds. This energy will heat the resistor element from 40 °C (104 °F) to the maximum allowable temperature.

Continuous power (heat) dissipation of the resistor when placed correctly. Energy E

R dissipates in 400 seconds.

630 kW possible if ambient temperature is below 33 °C (91 °F)

450 kW possible if ambient temperature is below 33 °C (91 °F)

Combined braking cycles

• After P br5

, P br10

or P br30

braking, the drive and the chopper will withstand P continuously. P brcont

is the only allowed braking power after P br5

, P br10

or P brcont br30

.

• P br5

, P br10

or P br30

braking is allowed once every minute.

• After P brcont

braking, there has to be a pause of at least 60 seconds without any braking if the subsequent braking power is greater than P brcont

.

Resistor braking


142

Example:

P br

P br5

, P br10

or P br30

P brcont

No braking max 5 s, 10 s or 30 s min. 60 s min. 60 s t

Brake resistor connection data

Voltage over the resistor during braking is 1.35 · 1.2 · 415 V DC when the supply voltage is 380 to 415 VAC and 1.35 · 1.2 · 500 V DC when the supply voltage is 440 to 500 V AC.

SAFUR resistors

Degree of protection: IP00. The resistors are not UL listed.

Maximum resistor cable length

10 m (33 ft)

Dimensions and weights

234

Weight:

Weight:

SAFUR125F500: 25 kg

SAFUR200F500: 30 kg

SAFUR210F575: 27 kg

5 5

300

Ø 7

345

Resistor braking


Du/dt filters and sine filters


This chapter describes how to select du/dt filters for the drive.

du/dt filters

When is du/dt filter needed?

See section Checking the compatibility of the motor and drive , page 58 .

Selection table du/dt filter types for the drive module types are given below.

Drive type du/dt filter type

ACS850-04-430A-5 FOCH-0320-50

ACS850-04-521A-5 FOCH-0320-50

ACS850-04-602A-5 FOCH-0320-50

ACS850-04-693A-5 FOCH-0610-70

ACS850-04-720A-5 FOCH-0610-70

00581898

Description, installation and technical data of the FOCH filters

See FOCH du/dt Filters Hardware Manual (3AFE68577519 [English]).

Sine filters

Contact your local ABB representative.

143

Du/dt filters and sine filters


144

Du/dt filters and sine filters


Further information

Product and service inquiries

Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to ABB website and selecting Sales, Support and Service network .

Product training

For information on ABB product training, navigate to ABB website and select Training courses .

Providing feedback on ABB Drives manuals

Your comments on our manuals are welcome. Go to ABB website and select

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

Document library on the Internet

You can find manuals and other product documents in PDF format on the Internet.

Go to ABB website and select Document Library.

You can browse the library or enter selection criteria, for example a document code, in the search field.


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