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ACS800-U4
ABB ACS800-U4 User Manual
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ACS800-04 Drive Modules
0.55 t
o 20
0 kW
ACS800-U4 Drive Module
s
0.75 to 200
HP
Hardware Manual
3AFE68372984 Rev E EN
EFFECTIVE: 31.03.2008
©
2008 A
BB Oy. Al
l Rights
Reserved.
Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: info@clrwtr.com
2
4
Table of Contents
Default Chapter
10
ACS800 Single Drive Manuals
10
Safety Instructions
13
What this Chapter Contains
13
Use of Warnings and Notes
13
Installation and Maintenance Work
14
Grounding
15
Mechanical Installation and Maintenance
16
Printed Circuit Boards
16
Fibre Optic Cables
16
Operation
17
Permanent Magnet Motor
18
Installation and Maintenance Work
18
Start-Up and Operation
18
Table of Contents
19
Table of Contents
25
About this Manual
25
What this Chapter Contains
25
Compatibility
25
Intended Audience
25
Categorization According to the Frame Size
25
Categorization According to the + Code
25
Contents
26
Installation and Commissioning Flowchart
27
Product and Service Inquiries
28
Product Training
28
Providing Feedback on ABB Drives Manuals
28
Terms and Abbreviations
29
Acs800-04/U4
31
What this Chapter Contains
31
Layout
31
Type Code
32
Main Circuit and Control
33
Diagram
33
Operation
34
Printed Circuit Boards
34
Motor Control
34
Planning the Cabinet Assembly
35
What this Chapter Contains
35
Cabinet Construction
35
Disposition of the Devices
35
Grounding of Mounting Structures
35
Free Space Around the Unit
36
Cooling and Degrees of Protection
37
Preventing the Recirculation of Hot Air
38
Outside the Cabinet
38
Inside the Cabinet
39
Cabinet Layout Example
39
Cabinet Heaters
40
Mounting the Optional Control Panel
40
Installing the Control Panel Directly on the Cabinet Door
40
Control Panel Mounting Platform Kit (RPMP)
41
EMC Requirements
41
Mechanical Installation
43
Unpacking the Unit
43
Delivery Check
44
Before Installation
44
Requirements for the Installation Site
44
Floor
44
Installation Procedure
45
Flange Mounting
46
Planning the Electrical Installation
49
What this Chapter Contains
49
Motor Selection and Compatibility
49
Protecting the Motor Insulation and Bearings
50
Requirements Table
51
Permanent Magnet Synchronous Motor
54
Supply Connection
54
Disconnecting Device (Means)
54
EEA / Europe
55
Main Contactor
55
Fuses
55
Thermal Overload and Short-Circuit Protection
55
Thermal Overload Protection of the Drive and the Input and Motor Cables
55
Thermal Overload Protection of the Motor
56
Protection against Short-Circuit in the Motor Cable
56
Protection against Short-Circuit Inside the Drive or in the Supply Cable
56
Ground Fault Protection
57
Emergency Stop Devices
57
Prevention of Unexpected Start
58
Selecting the Power Cables
59
General Rules
59
Alternative Power Cable Types
60
Motor Cable Shield
60
Additional US Requirements
61
Conduit
61
Armored Cable / Shielded Power Cable
61
Power Factor Compensation Capacitors
62
Equipment Connected to the Motor Cable
62
Installation of Safety Switches, Contactors, Connection Boxes, Etc
62
Bypass Connection
62
Before Opening a Contactor (DTC Control Mode Selected)
63
Protecting the Relay Output Contacts and Attenuating Disturbances in Case of Inductive Loads
63
Selecting the Control Cables
64
Relay Cable
64
Control Panel Cable
64
Connection of a Motor Temperature Sensor to the Drive I/O
65
Installation Sites above 2000 Metres (6562 Feet)
65
Routing the Cables
65
Control Cable Ducts
66
Electrical Installation
67
What this Chapter Contains
67
Checking the Insulation of the Assembly
67
Drive
67
Input Cable
67
Motor and Motor Cable
67
IT (Ungrounded) Systems
68
Power Cable Connection
69
Connecting the Power Cables
69
Grounding the Motor Cable Shield at the Motor End
70
Frame Sizes R2 to R4
71
Frame Size R5
71
Frame Size R6: Cable Lug Installation [16 to 70 Mm2 (6 to 2/0 AWG) Cables]
72
Power Cable Protection
73
Frame Size R5
73
Frame Size R6
74
Warning Sticker
74
Connecting the Control Cables
75
Terminals
75
Degrees Grounding
77
When the Outer Surface of the Shield Is Covered with Non-Conductive Material
77
Connecting the Shield Wires
77
Cabling of I/O and Fieldbus Modules
78
Pulse Encoder Module Cabling
78
Installation of Optional Modules and PC
79
Fibre Optic Link
79
External +24 V Power Supply for the RMIO Board Via Terminal X34
79
Parameter Settings
79
Connecting +24 V External Power Supply
79
Prevention of Unexpected Start, AGPS Board
82
Motor Control and I/O Board (RMIO)
85
What this Chapter Contains
85
Note on Terminal Labelling
85
Note on External Power Supply
85
Parameter Settings
85
External Control Connections (Non-US)
86
External Control Connections (US)
87
RMIO Board Specifications
88
Analogue Inputs
88
Constant Voltage Output
88
Auxiliary Power Output
88
Analogue Outputs
88
Digital Inputs
88
Relay Outputs
89
DDCS Fibre Optic Link
89
24 V DC Power Input
89
Installation Checklist
91
Checklist
91
Maintenance
93
What this Chapter Contains
93
Safety
93
Maintenance Intervals
93
Heatsink
93
Fan
94
Fan Replacement (R2, R3)
94
Fan Replacement (R4)
95
Fan Replacement (R5)
96
Fan Replacement (R6)
97
Additional Fan
97
Replacement (R2, R3)
97
Replacement (R4, R5)
98
Replacement (R6)
98
Capacitors
98
Reforming
98
Leds
98
Technical Data
99
What this Chapter Contains
99
IEC Data
99
Ratings
99
Symbols
101
Sizing
101
Derating
102
Temperature Derating
102
Altitude Derating
102
Cooling Characteristics
102
Cooling Requirements for Flange Mounting
102
Fuses
103
Frame Sizes R2 to R4
103
Frame Sizes R5 and R6
104
Calculation Example
105
Gg Fuses
106
Ultrarapid (Ar) Fuses
107
Quick Guide for Selecting between Gg and Ar Fuses
108
Cable Types
109
Cable Entries
110
Dimensions, Weights and Noise
110
NEMA Data
111
Ratings
111
Symbols
112
Sizing
112
Derating
112
Fuses
113
Cable Types
114
Cable Entries
115
Dimensions, Weights and Noise
115
Input Power Connection
115
Motor Connection
116
Efficiency
116
Cooling
116
Degrees of Protection
116
Agps-11C
117
Ambient Conditions
117
Materials
118
Applicable Standards
118
CE Marking
119
Definitions
119
Compliance with the EMC Directive
119
Compliance with the en 61800-3 (2004)
119
First Environment (Drive of Category C2)
119
Second Environment (Drive of Category C3)
120
Second Environment (Drive of Category C4)
120
Machinery Directive
120
C-Tick" Marking
121
Definitions
121
Compliance with IEC 61800-3
121
First Environment (Drive of Category C2)
121
Second Environment (Drive of Category C3)
122
Second Environment (Drive of Category C4)
122
Marine Type Approvals
122
UL/CSA Markings
123
Equipment Warranty and Liability
123
Product Protection in the US
124
Dimensional Drawings
125
What this Chapter Contains
125
Frame Size R2 (with Optional Control Panel)
126
Frame Size R3 (with Optional Control Panel)
127
Frame Size R4 (with Optional Control Panel)
128
Frame Size R5 (with Optional Control Panel)
129
Frame Size R6 (with Optional Control Panel)
130
Flange Mounting Kits
131
Flange Mounting Kit for Frame Size R2
132
Flange Mounting Kit for Frame Size R3
133
Flange Mounting Kit for Frame Size R4
134
Flange Mounting Kit for Frame Size R5
135
Flange Mounting Kit for Frame Size R6
136
AGPS Board
137
Resistor Braking
139
What this Chapter Contains
139
Availability of Brake Choppers and Resistors
139
How to Select the Correct Drive/Chopper/Resistor Combination
139
Optional Brake Chopper and Resistor(S)
140
Resistor Installation and Wiring
142
Protection of Frame Sizes R2 to R5
143
Protection of Frame Size R6
144
Brake Circuit Commissioning
144
4
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ABB ACS800-U4 Specifications
General
Brand
ABB
Model
ACS800-U4
Category
Controller
Language
English
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