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ABB ACS800 Series Hardware Manual
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ABB ACS800 Series Hardware Manual

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ACS800
Hardware Manual
ACS800-11 Drives (5.5 to 110 kW)
ACS800-U11 Drives (7.5 to 125 hp)

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Summary of Contents for ABB ACS800 Series

  • Page 1 ACS800 Hardware Manual ACS800-11 Drives (5.5 to 110 kW) ACS800-U11 Drives (7.5 to 125 hp)

  • Page 2: List Of Related Manuals

    You can find manuals and other product documents in PDF format on the Internet. See section Document library on the Internet on the inside of the back cover. For manuals not available in the Document library, contact your local ABB representative. ACS800-11/U11 manuals...
  • Page 3 ACS800-11 Drives 5.5 to 110 kW ACS800-U11 Drives 7.5 to 125 hp Hardware Manual 3AFE68367883 Rev C EFFECTIVE: 2013-03-04  2013 ABB Oy. All Rights Reserved.

  • Page 5: Safety Instructions

    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.

  • Page 6: Installation And Maintenance Work

    Installation and maintenance work These warnings are intended for all who work on the drive, motor cable or motor. WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment: • Only qualified electricians are allowed to install and maintain the drive. •...

  • Page 7: Grounding

    • At installation sites above 2000 m (6562 ft), the terminals of the RMIO board and optional modules attached to the board do not fulfil the Protective Extra Low Voltage (PELV) requirements stated in EN 50178 and EN 61800-5-1. • The Prevention of unexpected start-up function (option +Q950) does not remove the voltage from the main and auxiliary circuits.

  • Page 8: Mechanical Installation And Maintenance

    Mechanical installation and maintenance 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. • ACS800-11: The drive is heavy. Do not lift it alone. Do not lift the unit by the front cover.

  • Page 9: Printed Circuit Boards

    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. Fibre optic cables WARNING! Ignoring the following instructions can cause equipment malfunction and damage to the fibre optic cables:...

  • Page 10: Operation

    Operation 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.

  • Page 11: Permanent Magnet Motor

    Permanent magnet motor These are additional warnings concerning permanent magnet motor drives. Ignoring the instructions can cause physical injury or death, or damage to the equipment. Note: Controlling a permanent magnet motor is only allowed using the ACS800 Permanent Magnet Synchronous Motor Drive Control Program. Installation and maintenance work WARNING! Do not work on the drive when the permanent magnet motor is rotating.
  • Page 12 Safety instructions...

  • Page 13: Table Of Contents

    Table of contents List of related manuals ............2 Safety instructions What this chapter contains .
  • Page 14 Mechanical installation What this chapter contains ............37 Unpacking the unit.
  • Page 15 Power factor compensation capacitors ..........63 Equipment connected to the motor cable.
  • Page 16 Start-up and validation ............85 Use .
  • Page 17 Line-side converter actual signals and parameters in the motor-side converter control program . 103 Terms and abbreviations ........... 103 Actual signals .
  • Page 18 Ratings ..............120 Symbols .
  • Page 19 Providing feedback on ABB Drives manuals ........
  • Page 20 Table of contents...

  • Page 21: Introduction To This Manual

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

  • Page 22: Contents

    Contents The chapters of this manual are briefly described below. Safety instructions give safety instructions for the installation, commissioning, operation and maintenance of the drive. Introduction to this manual lists the steps in checking the delivery and installing and commissioning the drive and refers to chapters/sections in this manual and other manuals for particular tasks.

  • Page 23: Installation And Commissioning Flowchart

    Installation and commissioning flowchart Task Identify the frame size of your drive: R5 or R6. Technical data / IEC data NEMA data Plan the installation. Technical data Check the ambient conditions, ratings, required Planning the electrical installation cooling air flow, input power connection, compatibility For compliance with the European Union EMC of the motor, motor connection, and other technical Directive, see...

  • Page 24: Terms And Abbreviations

    Task Connect the power cables. Electrical installation Connect the motor cable. Connect the control and auxiliary control cables. Electrical installation, Motor control and I/O board (RMIO), and the optional module manual delivered with the module. Check the installation. Installation checklist Commission the drive.
  • Page 25 RCAN CANopen adapter module RCNA ControlNet adapter module RDCO DDCS communication module RDIO Digital I/O extension module RDNA DeviceNet™ adapter module RETA Ethernet adapter module for Modbus/TCP and EtherNet/IP protocols Radio-frequency interference RIBA InterBus-S adapter module RLON ® adapter module ORKS RMBA Modbus adapter module...
  • Page 26 Introduction to this manual...

  • Page 27: Operation Principle And Hardware Description

    Operation principle and hardware description What this chapter contains This chapter describes the operating principle and construction of the drive in short. Product overview The ACS800-11/U11 is a four-quadrant wall mountable drive for controlling AC motors. The main circuit consists of two IGBT converters, a line-side converter and a motor-side converter, integrated into the same frame.
  • Page 28 Motor-side converter RMIO board I/O terminals Line-side converter RMIO board U1 V1 U2 V2 W2 Power cable terminals Frame size R5 without front and connection box covers Operation principle and hardware description...
  • Page 29 Line-side converter RMIO board Motor-side converter RMIO board I/O terminals Power cable terminals Frame size R6 without front and connection box covers Operation principle and hardware description...

  • Page 30: Terms

    Terms Line-side converter: A converter that is connected to the supply network and is capable of transferring energy from the network to the DC link or from the DC link to the network. Motor-side converter: A converter that is connected to the motor and controls the motor operation.

  • Page 31: Ac Voltage And Current Waveforms

    AC voltage and current waveforms The AC current is sinusoidal at a unity power factor. The IGBT supply unit does not generate characteristic current or voltage overtones like a traditional 6- or 12-pulse bridge does. The Total Harmonic Distortion (THD) in current is given in chapter Technical data: Input power connection.

  • Page 32: Motor Control

    Motor control The motor control is based on the Direct Torque Control (DTC) method. Two phase currents and DC link voltage are measured and used for the control. The third phase current is measured for earth fault protection. Printed circuit boards The drive contains the following printed circuit boards as standard: •...

  • Page 33: Main Circuit And Control Diagram

    Main circuit and control diagram Operation principle and hardware description...

  • Page 34: Fieldbus Control Interface

    Fieldbus control interface Optional fieldbus modules cannot be inserted in the optional module slots of the RMIO board of the line-side converter. Fieldbus control of the line-side converter is performed via the motor-side converter RMIO board as shown in the block diagram below.

  • Page 35: Connection Diagram Of The Rmio Board In The Line-Side Converter

    Connection diagram of the RMIO board in the line-side converter Internal connections to the RMIO board for the ACS800 IGBT Supply Control Program are shown below. Do not change the connections. Terminal block size: VREF- Reference voltage -10 VDC, 1 kohm < R <...

  • Page 36: Type Code

    Type code The type code contains information on the specifications and configuration of the drive. The first digits from left express the basic configuration (for example, ACS800-11-0025-3 or ACS800-U11-0025-3). The optional selections are given thereafter, separated by plus signs (for example, +E200 and +K454). The main selections are described below.

  • Page 37: Mechanical Installation

    Mechanical installation What this chapter contains This chapter contains unpacking instructions, the delivery checklist and the mechanical installation instructions of the drive. Unpacking the unit The drive is delivered in a box that also contains: • plastic bag containing: screws (M3), clamps and cable lugs (2 mm , M3) for grounding the control cable screens •...

  • Page 38: Checking The Delivery

    To unpack the package, cut the bands (A) and remove the outer box (B) and sleeve (C). 3AUA0000075717 Checking the delivery Check that all items listed in section 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.

  • Page 39: Moving The Unit

    The type designation label is attached to the heatsink and the serial number label to the lower part of the back plate of the unit. Example labels are shown below. Type designation label Serial number label Moving the unit Lift the unit using the lifting holes at the top and bottom. Lifting a unit of frame size R6 Mechanical installation...

  • Page 40: Before Installation

    Before installation The drive must be installed in an upright position with the cooling section facing a wall. Check the installation site according to the requirements below. Refer to chapter Dimensional drawings for frame details. WARNING! Do not remove the protective film that covers the unit before the installation procedure is complete.

  • Page 41: Free Space Around The Unit

    Free space around the unit Required free space around the drive to enable cooling air flow, service and maintenance is shown below in millimetres and [inches]. 200 [7.9] 50 [2.0] 50 [2.0] 200 [7.9] IP21 (UL 1) Cooling air flow Mounting the drive on the wall Units without vibration dampers 1.

  • Page 42: Cabinet Installation

    Appropriate vibration dampers are GC3-50MS (kit code 68295581): • for units of frame size R5, four dampers • for units of frame size R6, six dampers Note that the kit only includes four vibration dampers, but units of frame size R6 require six.

  • Page 43: Unit Above Another

    Unit above another Lead the out-coming hot cooling air away from the air input of the drive above. Example max.+40 °C (+104 °F) Installing cabinet duct plates (optional) If the drive is installed in a cabinet that is inside a cooling air duct, duct plates can be used to lead the air flow.

  • Page 44: Before You Start

    Screws are not included in the installation kit. The following screws are needed: • frame size R5: 18 pieces: M5X12, torque 3 N·m (2.2 lbf·ft) 2 pieces: M4X16, torque 1.2 N·m (0.9 lbf·ft) 2 pieces: M4X12, torque 1.2 N·m (0.9 lbf·ft) •...

  • Page 45: Assembly Drawing For Cabinet Duct Plates

    Assembly drawing for cabinet duct plates Mechanical installation...
  • Page 46 Mechanical installation...

  • Page 47: Planning The Electrical Installation

    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.

  • Page 48: Protecting The Motor Insulation And Bearings

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

  • Page 49: Requirements Table

    Motor type Nominal mains Requirement for voltage (AC line Motor insulation ABB du/dt filter, insulated N-end bearing and ABB common mode voltage) system filter < 100 kW 100 kW < P <...
  • Page 50 Motor type Nominal mains Requirement for voltage (AC line Motor insulation ABB du/dt filter, insulated N-end bearing and ABB common mode voltage) system filter < 100 kW 100 kW < P < 350 kW > 350 kW frame size > IEC 315 frame size <...
  • Page 51 Note 3: ABB high-output motors and IP23 motors The rated output power of high output motors is higher than what is stated for the particular frame size in EN 50347:2001. This table shows the requirements for ABB random-wound motor series (for example, M3AA, M3AP and M3BP).
  • Page 52 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 6: ABB motors of types other than M2_, M3_, HX_ and AM_ Use the selection criteria given for non-ABB motors. Planning the electrical installation...
  • Page 53 Note 7: 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.

  • Page 54: Permanent Magnet Motor

    Permanent magnet motor Only one permanent magnet motor can be connected to the inverter output. It is recommended to install a safety switch between the permanent magnet motor and the drive output. The switch is needed to isolate the motor during any maintenance work on the drive.

  • Page 55: Short-Circuit Protection

    Short-circuit protection Protect the input cable and drive against short-circuit according to the following guide lines. Circuit diagram Drive type Short-circuit protection DRIVE IS NOT EQUIPPED WITH INPUT FUSES ACS800-11 Protect the drive and input cable with fuses. Drive or drive Distribution ACS800-U11 See footnote 1).

  • Page 56: Ground Fault Protection

    Ground fault protection The drive is equipped with an internal ground fault protective function to protect the unit against ground faults in the motor and 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 ACS800 Firmware Manual.

  • Page 57: Prevention Of Unexpected Start-Up (Option +Q950)

    Prevention of unexpected start-up (option +Q950) The ACS800-11/U11 can be equipped with an optional Prevention of unexpected start-up function according to standards: • IEC/EN 60204-1:1997, • ISO/DIS 14118:2000, • EN 1037:1996, • EN ISO 12100:2003, • EN 954-1:1996, • EN ISO 13849-2:2003. The Prevention of unexpected start-up (POUS) function disables the control voltage of the power semiconductors, thus preventing the drive from generating the AC voltage required to rotate the motor.

  • Page 58: Safe Torque Off (Option +Q967)

    Safe torque off (option +Q967) The drive supports the Safe torque off (STO) function according to standards: • EN 61800-5-2:2007, • EN ISO 13849-1:2008, • IEC 61508, • IEC 61511:2004, • EN 62061:2005. The function also corresponds to Prevention of unexpected start-up of EN 1037. The STO may be used where power removal is required to prevent an unexpected start-up.

  • Page 59: Safe Torque Off Circuit Diagram

    Safe torque off circuit diagram Planning the electrical installation...

  • Page 60: Selecting The Power Cables

    Selecting the power cables General rules Dimension the mains (input power) and motor cables according to local regulations: • The cable must be able to carry the drive load current. See chapter Technical data for the rated currents. ° ° •...

  • Page 61: Alternative Power Cable Types

    Alternative power cable types Power cable types that can be used with the drive are represented below. Recommended Symmetrical shielded cable: three phase conductors A separate PE conductor is required if the conductivity and a concentric or otherwise symmetrically of the cable shield is < 50 % of the conductivity of the constructed PE conductor, and a shield phase conductor.

  • Page 62: Additional Us Requirements

    Additional US requirements Type MC continuous corrugated aluminium armor cable with symmetrical grounds or shielded power cable must be used for the motor cables if metallic conduit is not used. For the North American market, 600 VAC cable is accepted for up to 500 VAC. 1000 VAC cable is required above 500 VAC (below 600 VAC).

  • Page 63: Power Factor Compensation Capacitors

    Power factor compensation capacitors 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 to the motor cables (between the drive and the motor).

  • Page 64: Using A Contactor Between The Drive And The Motor

    Using a contactor between the drive and the motor Implementing the control of the output contactor depends on how you select the drive to operate. When you have selected to use DTC motor control mode, and motor ramp stop, open the contactor as follows: 1.

  • Page 65: Protecting The Relay Output Contacts And Attenuating Disturbances In Case Of Inductive Loads

    Protecting the relay output contacts and attenuating disturbances in case of inductive loads Inductive loads (relays, contactors, motors) cause voltage transients when switched off. The relay contacts on the RMIO board 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.

  • Page 66: Selecting The Control Cables

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

  • Page 67: Connection Of A Motor Temperature Sensor To The Drive I/O

    Connection of 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 non- conductive 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:...

  • Page 68: Control Cable Ducts

    A diagram of the cable routing is shown below. Motor cable Drive min 300 mm (12 in.) Power cable Input power cable Motor cable 90 ° min 200 mm (8 in.) min 500 mm (20 in.) Control cables Control cable ducts 230 V 230 V (120 V)

  • Page 69: Electrical Installation

    Electrical installation What this chapter contains This chapter describes the electrical installation procedure of the drive. WARNING! The work described in this chapter may only be carried out by a qualified electrician. Follow the Safety instructions on the first pages of this manual. Ignoring the safety instructions can cause injury or death.

  • Page 70: Motor And Motor Cable

    2. Measure the insulation resistance between each phase conductor and the Protective Earth conductor using a measuring voltage of 1000 V DC. The insulation resistance of an ABB motor must exceed 100 Mohm (reference value at 25 °C or 77 °F). For the insulation resistance of other motors, please consult the manufacturer’s instructions.

  • Page 71: Disconnecting The Emc Filter Capacitors

    Disconnecting the EMC filter capacitors Units of frame size R5 Remove the two screws shown below. Note: Depending on the EMC filter type and the nominal voltage of the drive, there may be only one screw. View of frame size R5 Note: When the capacitors of EMC filter +E202 or +E200 are disconnected, the EMC Directive requirements in the second environment will not be fulfilled.

  • Page 72: Connecting The Power Cables

    Connecting the power cables Diagram Drive OUTPUT INPUT UDC+ UDC V1 W1 V2 W2 (PE) (PE) For alternatives, see Planning the electrical Motor installation: Disconnecting device (disconnecting means) 1), 2) Grounding of the motor cable shield at the motor end If shielded cable is used (not required but For minimum radio frequency interference: recommended), use a separate PE cable (1) or a...

  • Page 73: Conductor Stripping Lengths

    Conductor stripping lengths Strip the conductor ends as follows to fit them inside the power cable connection terminals. Frame size Stripping length 0.63 1.10 Allowed wire sizes, tightening torques Technical data: Cable entries. Wall installed units (European version) Power cable installation procedure 1.
  • Page 74 Views of frame size R5 UDC+ UDC- Electrical installation...
  • Page 75 Frame sizes R6: Cable lug installation [16 to 70 mm (6 to 2/0 AWG) cables] Remove the screw terminals. Fasten the cable lugs to the remaining bolts with M10 nuts. Isolate the ends of the cable lugs with insulating tape or shrink tubing.

  • Page 76: Wall Installed Units (Us Version)

    Wall installed units (US version) 1. Remove the connection box cover. 2. Remove the front cover by releasing the retaining clip with a screw driver and lifting the cover from the bottom outwards. 3. Remove the gland plate by undoing the fastening screws. 4.

  • Page 77: Warning Sticker

    Wire size Compression lug Crimping tool kcmil/AWG Manufacturer Type Manufacturer Type No. of crimps Burndy YA4C-L4BOX Burndy MY29-3 Ilsco CCL-4-38 Ilsco MT-25 Burndy YA2C-L4BOX Burndy MY29-3 Ilsco CRC-2 Ilsco IDT-12 Ilsco CCL-2-38 Ilsco MT-25 Burndy YA1C-L4BOX Burndy MY29-3 Ilsco CRA-1-38 Ilsco IDT-12 Ilsco...

  • Page 78: Connecting The Control Cables

    Connecting the control cables Lead the cable through the control cable entry (1). Connect the control cables as described below. Connect the conductors to the appropriate detachable terminals of the RMIO board [refer to chapter Motor control and I/O board (RMIO)].

  • Page 79: 360 Degrees Grounding

    360 degrees grounding Insulation Double-shielded cable Single-shielded cable When the outer surface of the shield is covered with non-conductive material: • Strip the cable carefully (do not cut the grounding wire and the shield) • Turn the shield inside out to expose the conductive surface. •...

  • Page 80: Cabling Of I/O And Fieldbus Modules

    Cabling of I/O and fieldbus modules Module As short as possible Shield Note: The RDIO module does not include a terminal for cable shield grounding. Ground the pair cable shields here. Pulse encoder module cabling Note 1: If the encoder is of unisolated type, ground the encoder cable at the drive end only.

  • Page 81: Fastening The Control Cables And Covers

    Fastening the control cables and covers When all control cables are connected, fasten them together with cable ties. Units with a connection box: fasten the cables to the entry plate with cable ties. Units with a gland box: tighten the clamping nuts of the cable glands. Fasten the connection box cover.

  • Page 82: Connecting A Pc To The Motor-Side Rmio Board

    In the example below, one AIMA-01 I/O module adapter is connected to the RMIO boards of the line-side and motor-side converters. RMIO board of RMIO board of the line-side the motor-side converter converter *) RDCO RDCO AIMA-01 I/O module adapter *) WARNING! In frame size R6, you must remove the top cover to reach the RMIO board.

  • Page 83: What This Chapter Contains

    Installation of the AGPS board (Prevention of unexpected start-up, +Q950) What this chapter contains This chapter describes the electrical installation of the optional Prevention of unexpected start-up function (+Q950) of the drive. Prevention of unexpected start-up (+Q950) The optional Prevention of unexpected start-up function includes an AGPS board which is connected to the drive and an external power supply.
  • Page 84 Connect the AGPS board as follows: • Remove the enclosure cover by undoing the fixing screws (1). • Ground the bottom plate of the enclosure or via terminal X1:1 of the AGPS board. • Connect the cable delivered with the kit between terminal block X2 of the AGPS board (2) and drive terminal block X41.

  • Page 85: Circuit Diagram

    Circuit diagram This circuit diagram shows how the AGPS-11 kit is installed. Drive 115/230 VAC 3AFE00374994 Start-up and validation Action Follow the safety instructions, see section Safety instructions on page Ensure that the drive can be run and stopped freely during the start-up. Stop the drive (if running), switch the input power off and isolate the drive from the power line by a disconnector.

  • Page 86: Use

    Activate the function as follows: • Stop the drive. Use the stop key of the panel (local mode) or give the stop command through the I/O or fieldbus interface. • Open the switch activating the Prevention of unexpected start-up function of the drive.

  • Page 87: Installation Of The Asto Board (Safe Torque Off, +Q967)

    Installation of the ASTO board (Safe torque off, +Q967) What this chapter contains This chapter describes the electrical installation of the optional Safe torque off function (+Q967) of the drive and the specifications of the board. Safe torque off (+Q967) The optional Safe torque off function includes an ASTO board, which is connected to the drive and an external power supply.
  • Page 88 • page 27 for location of terminal block X41 of the drive • page for the circuit diagram • page for the dimensions of the ASTO-11C board • section ASTO-11C (option +Q967) in chapter Technical data for the technical data of the ASTO-11C board.

  • Page 89: Circuit Diagram

    Circuit diagram The diagram below shows the connection between the ASTO board and the drive when it is ready. For an example diagram of a complete Safe torque off circuit, see page 59. 3AUA0000072542 Validation and start-up Validate and start-up the function according to the instructions given in ACS800- 01/04/11/31/104/104LC Safe torque off function (+Q967), Application guide (3AUA0000063373 [English]).
  • Page 90 Installation of the ASTO board (Safe torque off, +Q967)

  • Page 91: Motor Control And I/O Board (Rmio)

    Motor control and I/O board (RMIO) What this chapter contains This chapter shows • external control connections to the RMIO board for the ACS800 Standard Control Program (Factory Macro) • specifications of the inputs and outputs of the board. Note on terminal labelling Optional modules (Rxxx) may have identical terminal designations with the RMIO board.

  • Page 92: External Control Connections (Non-Us)

    External control connections (non-US) External control cable connections to the RMIO board for the ACS800 Standard Control Program (Factory Macro) are shown below. For external control connections of other application macros and programs, see the appropriate Firmware Manual. RMIO RMIO VREF- Reference voltage -10 VDC, 1 kohm <...

  • Page 93: External Control Connections (Us)

    External control connections (US) External control cable connections to the RMIO board for the ACS800 Standard Control Program (Factory Macro US version) are shown below. For external control connections of other application macros and programs, see the appropriate Firmware Manual. RMIO RMIO VREF-...

  • Page 94: Rmio Board Specifications

    RMIO board specifications Analogue inputs Two programmable differential current inputs (0 mA / 4 mA ... 20 mA, R = 100 ohm) and one programmable differential voltage input (-10 V / 0 V / 2 V ... +10 V, R >...

  • Page 95: Relay Outputs

    Maximum continuous current 2 A rms Isolation test voltage 4 kVAC, 1 minute DDCS fibre optic link With optional communication adapter module RDCO. Protocol: DDCS (ABB Distributed Drives Communication System) 24 VDC power input Voltage 24 VDC ± 10% Typical current consumption...
  • Page 96 Isolation and grounding diagram (Test voltage: 500 V AC) VREF- AGND VREF+ AGND AI1+ Common mode AI1- voltage between AI2+ channels ±15 V AI2- AI3+ AI3- AO1+ AO1- AO2+ AO2- Jumper J1 settings: DGND1 All digital inputs share a common ground.

  • Page 97: Installation Checklist

    Installation checklist What this chapter contains This chapter contains an installation checklist. Checklist Check the mechanical and electrical installation of the drive before start-up. Go through the checklist below together with another person. WARNING! Only qualified electricians are allowed to commission the drive. Read and follow the Safety instructions on the first pages of this manual.
  • Page 98 Check that... There are no power factor compensation capacitors in the motor cable. The external control connections inside the drive are OK. There are no tools, foreign objects or dust from drilling inside the drive. Mains (input power) voltage cannot be applied to the output of the drive (with bypass connection).

  • Page 99: Start-Up And Use

    Start-up and use What this chapter contains This chapter describes the start-up procedure and use of the drive, and the control panel control of the line-side and motor-side converters. Start-up and use WARNING! Only qualified electricians are allowed to commission the drive. Read and follow the Safety instructions on the first pages of this manual.

  • Page 100: Control Panel

    Drives with option +Q950: Validate and perform the start-up procedure of the Prevention of unexpected start-up function according to instructions given in chapter Installation of the ASTO board (Safe torque off, +Q967). Drives with option +Q967: Validate and perform the start-up procedure of the Safe torque off function according to instructions given in ACS800- 01/04/11/31/104/104LC Safe torque off function (+Q967), Application guide (3AUA0000063373 [English]).

  • Page 101: To Control The Motor-Side Converter

    To control the motor-side converter... Step Action Press key Display (example) Enter the Drive Selection Mode. ACS 800 0050_5LR DRIVE IXXR7xxx ID-NUMBER 2 Scroll to ID number 1. ACS 800 0050_5MR ACXR7xxx ID-NUMBER 1 Verify the change to the motor-side converter. ->...
  • Page 102 Start-up and use...

  • Page 103: Actual Signals And Parameters

    Actual signals and parameters What this chapter contains This chapter contains listings of parameters specific to the ACS800-11 and ACS800-U11. Line-side converter actual signals and parameters in the motor-side converter control program This section describes the actual signals and parameters of the line-side converter control program which are copied to the motor-side converter control program.

  • Page 104: Actual Signals

    Actual signals Name/Value Description FbEq Def. 09 ACTUAL SIGNALS Signals from the line converter. 09.12 LCU ACT SIGNAL 1 Line converter signal selected by par. 95.08 LCU PAR1 SEL. 1 = 1 09.13 LCU ACT SIGNAL 2 Line converter signal selected by par. 95.09 LCU PAR2 SEL. 1 = 1 Parameters Name/Value...

  • Page 105: Acs800-11/U11 Specific Parameters In The Igbt Supply Control Program

    ACS800-11/U11 specific parameters in the IGBT Supply Control Program The signals and parameters of the IGBT Supply Control Program which are specific to the ACS800-11 and ACS800-U11 are described in the tables below. These parameters need not be set in a normal start-up. For more information on parameters of the IGBT Supply Control Program, refer to ACS800 IGBT Supply Control Program Firmware Manual [3AFE68315735 (English)].

  • Page 106: 31 Automatic Reset

    Name/Value Description T./FbEq Def. 31 AUTOMATIC RESET Automatic fault reset. Automatic resets are possible only for certain fault types and when the automatic reset function is activated for that fault type. The automatic reset function is not operational if the drive is in local control (L visible on the first row of the control panel display).

  • Page 107: Fixed Parameters With The Acs800-11 And Acs800-U11

    Fixed parameters with the ACS800-11 and ACS800-U11 When the IGBT Supply Control Program is loaded into the ACS800-11 or ACS800-U11, the following parameters are set to the default values given in the table below. Parameter Default value If changed, 11.01 DC REF SELECT FIELDBUS the default values will be...
  • Page 108 Actual signals and parameters...

  • Page 109: Maintenance

    Change of additional cooling Additional fan. Every 6 years Main cooling fan change Main cooling fan. Every 10 years Capacitor change See Capacitors. Consult your local ABB Service representative for more details on the maintenance. On the Internet, go to http://www.abb.com/drivesservices. Maintenance...

  • Page 110: Heatsink

    If the drive is operated in a critical part of a process, fan replacement is recommended once these symptoms start appearing. Replacement fans are available from ABB. Do not use other than ABB specified spare parts.

  • Page 111: Fan Replacement (R5, R6)

    Fan replacement (R5, R6) 1. Loosen the fastening screws of the top plate. 2. Push the top plate backwards. 3. Lift the top plate up. 4. Disconnect the fan supply wires (detachable connector). 5. Lift the fan up. 6. Install the new fan in reverse order. Additional fan Replacement (R5) Remove the front cover.

  • Page 112: Replacement (R6)

    It is not possible to predict a capacitor failure. Capacitor failure is usually followed by a mains 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.

  • Page 113: Fault Tracing

    Fault tracing What this chapter contains This chapter describes the fault and warning messages displayed on the control panel and the LEDs of the drive. For a detailed description of the fault and warning messages, see the appropriate firmware manual. Faults and warnings displayed by the CDP 312R control panel The control panel displays the Warning and Fault messages of the unit (that is, line- side converter or motor-side converter) the panel is currently controlling.

  • Page 114: Leds

    • Reconnect the panel cable to the RMIO board of the motor-side converter again and set the ID number to 1. LEDs This table describes LEDs of the drive. Where When the LED is lit RMIO board * Drive in fault state Green The power supply on the board is OK.

  • Page 115: Technical Data

    Technical data What this chapter contains This chapter contains the technical specifications of the drive, e.g. the ratings, sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings and warranty policy. IEC data Ratings The IEC ratings for the ACS800-11 with 50 Hz and 60 Hz supplies are given below. The symbols are described below the table.

  • Page 116: Symbols

    Symbols Nominal ratings continuous rms output current. No overload capability at 40 °C (104 °F). cont.max maximum output current. Available for 10 s at start, otherwise as long as allowed by drive temperature. Typical ratings: No-overload use typical motor power. The power ratings apply to most IEC 60034 motors at the nominal cont.max voltage, 230 V, 400 V, 500 V or 690 V.

  • Page 117: Mains Cable Fuses

    Note 3: Fuses from other manufacturers can be used if they meet the ratings. ACS800-11 type Input Fuse current Manufacturer Type IEC size Three-phase supply voltage 208 V, 220 V, 230 V or 240 V -0011-2 9140 ABB Control OFAF000H40 -0016-2 15400 ABB Control OFAF000H50 -0020-2 21300 ABB Control OFAF000H63 -0025-2...
  • Page 118 aR fuses ACS800-11 type Input Fuse current Manufacturer Fuse Type DIN 43620 (@660V) size Three-phase supply voltage 208 V, 220 V, 230 V or 240 V -0011-2 1450 Bussmann 170M1565 -0016-2 2550 Bussmann 170M1566 -0020-2 4650 Bussmann 170M1567 -0025-2 8500 Bussmann 170M1568 -0030-2...

  • Page 119: Cable Types

    Cable types 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, ambient temperature 30 °C, PVC insulation, surface temperature 70 °C (158 °F) (EN 60204-1 and IEC 60364-5-2/2001).

  • Page 120: Nema Data

    NEMA data Ratings The NEMA ratings for the ACS800-U11 and ACS800-11 with 60 Hz supplies are given below. The symbols are described below the table. For sizing, derating and 50 Hz supplies, see data. ACS800-U11 type Normal use Heavy-duty use Frame Air flow Heat...

  • Page 121: Input Cable Fuses

    Input cable fuses The ratings of UL listed fuses for branch circuit protection are listed below. The fuses also prevent damage to the adjoining equipment of the drive in case of a short-circuit inside the drive. Check 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.

  • Page 122: Cable Types

    Cable types 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 current- carrying 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.

  • Page 123: Input Power Connection

    Input power connection Voltage (U 208/220/230/240 VAC 3-phase ± 10% for 230 VAC units 380/400/415 VAC 3-phase ± 10% for 400 VAC units 380/400/415/440/460/480/500 VAC 3-phase ± 10% for 500 VAC units 525/550/575/600/660/690 VAC 3-phase ± 10% for 690 VAC units The output voltage can be raised with setting of parameter 23.01 DC VOLT REF.

  • Page 124: Cooling

    Cooling Method Internal fan, flow direction from bottom to top. Free space around the unit See chapter Mechanical installation. Degree of protection IP21 (UL type 1). IPXXD from above. Without the front cover, the unit must be protected against contact according to IP2x, see chapter Electrical installation:...

  • Page 125: Ambient Conditions

    EU. They must be removed and handled according to local regulations. For further information on environmental aspects and more detailed recycling instructions, please contact your local ABB distributor. Technical data...

  • Page 126: Ce Marking

    Applicable standards The drive complies with the following standards. • EN 50178:1997 Electronic equipment for use in power installations • EN 60204-1:2006/ AC:2010 Safety of machinery. Electrical equipment of machines. Part 1: General requirements. Provisions for compliance: The final assembler of the machine is responsible for installing - an emergency-stop device - a supply disconnecting device.

  • Page 127: Compliance With En 61800-3:2004

    Compliance with EN 61800-3:2004 Definitions EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to operate without problems within an electromagnetic environment. Likewise, the equipment must not disturb or interfere with any other product or system within its locality. First environment includes establishments connected to a low-voltage network which supplies buildings used for domestic purposes.

  • Page 128: Second Environment (Drive Of Category C4)

    Equipment 2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available from the local ABB representative. 3. The motor and control cables are selected as specified in the Hardware Manual. 4. The drive is installed according to the instructions given in the Hardware Manual.

  • Page 129: Ul/Csa Markings

    UL/CSA markings The ACS800-U11 and ACS800-11 drives of UL type 1 are cULus listed and cCSAus certified. UL checklist • The drive is to be used in a heated, indoor controlled environment. The drive must be installed in clean air according to enclosure classification. Cooling air must be clean, free from corrosive materials and electrically conductive dust.
  • Page 130 Technical data...

  • Page 131: Dimensional Drawings

    Dimensional drawings The dimensions are given in millimetres and [inches]. Dimensional drawings...

  • Page 132: Frame Size R5 (Ip21, Ul Type 1)

    Frame size R5 (IP21, UL type 1) Dimensional drawings...

  • Page 133: Frame Size R6 (Ip21, Ul Type 1)

    Frame size R6 (IP21, UL type 1) Dimensional drawings...

  • Page 134: Cabinet Duct Plates (Optional), Frame Size R5

    Cabinet duct plates (optional), frame size R5 Dimensional drawings...

  • Page 135: Cabinet Duct Plates (Optional), Frame Size R6

    Cabinet duct plates (optional), frame size R6 Dimensional drawings...

  • Page 136: Package (Frame Size R5)

    Package (frame size R5) 1085 [42.72] 400 [15.75] Package (frame size R6) 1145 [45.08] 400 [15.75] Dimensional drawings...

  • Page 137: Agps Board With Enclosure (Optional)

    AGPS board with enclosure (optional) 3AFE68293898 Dimensional drawings...

  • Page 138: Asto Board With Enclosure (Optional)

    ASTO board with enclosure (optional) 3AUA0000068698 Dimensional drawings...

  • Page 139: External +24 V Power Supply For The Rmio Boards Via Terminal X34

    External +24 V power supply for the RMIO boards via terminal X34 What this chapter contains This chapter describes how to connect an external +24 V power supply for the RMIO boards of the motor-side and line-side converters via terminal X34. For current consumption of the RMIO board, see chapter Motor control and I/O board (RMIO).

  • Page 140: Connecting +24 V External Power Supply

    Connecting +24 V external power supply RMIO board of the motor-side converter 1. Break off the tab covering the +24 VDC power input connector with pliers. 2. Pull the connector outwards. 3. Disconnect the wires from the connector (keep the connector for later use). 4.
  • Page 141 RMIO board Connection of a two-way connector RMIO board Connection of a three-way connector External +24 V power supply for the RMIO boards via terminal X34...

  • Page 142: Rmio Board Of The Line-Side Converter

    RMIO board of the line-side converter Frame size R5 The location of terminal X34 in the line-side converter is shown below. Connect the external +24 V supply to the board as described in steps 2 to 8 in section RMIO board of the motor-side converter.
  • Page 143 9. Lift the upper plastic cover off. 10.Connect the external +24 V supply to the board as described in steps 2 to 5, 7 and 8 in section RMIO board of the motor-side converter. 11.Reconnect all disconnected cables and fasten the covers in reverse order. External +24 V power supply for the RMIO boards via terminal X34...
  • Page 144 External +24 V power supply for the RMIO boards via terminal X34...
  • Page 145 Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/drives...
  • Page 146 Contact us www.abb.com/drives www.abb.com/drivespartners...

This manual is also suitable for:

Acs800-11 seriesAcs800-u11 seriesAcs800-11-0011-2Acs800-11-0016-2Acs800-11-0020-2Acs800-11-0025-2 ... Show all

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