ABB ACS800 Series Hardware Manual
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ABB ACS800 Series Hardware Manual

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ACS800
Hardware Manual
ACS800-01 Drives (0.55 to 200 kW)
ACS800-U1 Drives (0.75 to 200 hp)
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Summary of Contents for ABB ACS800 Series

  • Page 1 ACS800 Hardware Manual ACS800-01 Drives (0.55 to 200 kW) ACS800-U1 Drives (0.75 to 200 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. ACS800-01/U1 manuals...
  • Page 3 ACS800-01 Drives 0.55 to 200 kW ACS800-U1 Drives 0.75 to 200 hp Hardware Manual 3AFE64382101 Rev K EFFECTIVE: 2013-06-27  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

    • The Prevention of unexpected start-up function (option +Q950) does not remove the voltage from the main and auxiliary circuits. • The Safe torque off function (option +Q967) does not remove the voltage from the main and auxiliary circuits. • At installation sites above 2000 m (6562 ft), the terminals of the RMIO board and option modules attached to the board do not fulfil the Protective Extra Low Voltage (PELV) requirements stated in EN 50178.

  • 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. • The drive is heavy. Do not lift it alone. Do not lift the unit by the front cover. Place the unit only on its back.

  • Page 9: 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 10: 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 11: Table Of Contents

    Table of contents List of related manuals ............2 Safety instructions What this chapter contains .
  • Page 12 Checking the delivery ............32 Before installation .
  • Page 13 Using a contactor between the drive and the motor........55 Protecting the relay output contacts and attenuating disturbances in case of inductive loads.
  • Page 14 Installation of the ASTO board (Safe torque off, +Q967) What this chapter contains ............83 Safe torque off (+Q967).
  • Page 15 Additional fan ..............102 Replacement (R2, R3) .
  • Page 16 CE marking ..............127 Compliance with the European Low Voltage Directive .
  • Page 17 Providing feedback on ABB Drives manuals ........
  • Page 18 Table of contents...

  • Page 19: 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 20: 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 21: Installation And Commissioning Flowchart

    Installation and commissioning flowchart Task Identify the frame size of your drive: R2, R3, R4, R5 Technical data: IEC data NEMA data or R6. 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 22: Terms And Abbreviations

    Task Check the insulation of the motor and the motor Electrical installation: Checking the insulation of cable. the installation Connect the power cables. Electrical installation Connect the control and the auxiliary control cables. Electrical installation, Motor control and I/O board (RMIO), and the option module manual delivered with the module.
  • Page 23 RDIO Digital I/O extension module RDNA DeviceNet™ adapter module RECA EtherCAT adapter module REPL Ethernet POWERLINK adapter module RETA Ethernet adapter module for Modbus/TCP and EtherNet/IP protocols Radio-frequency interference RIBA InterBus-S adapter module RINT Main circuit board RLON ® adapter module ORKS RMBA Modbus adapter module...
  • Page 24 Introduction to this manual...

  • Page 25: 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 ACS800-01/U1 is a wall mountable drive for controlling AC motors. Control panel CDP 312R Heat sink Front cover Connection box IP21 (UL type 1)

  • Page 26: 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, ACS800-01-0006-5). The optional selections are given thereafter, separated by + signs (for example, +E202). The main selections are described below. Not all selections are available for all types.

  • Page 27: Main Circuit And Control

    Main circuit and control Diagram This diagram shows the control interfaces and the main circuit of the drive. Drive Motor Option module 1: RMBA, RAIO, RDIO, control and RDNA, RLON, RIBA, RPBA, RCAN, I/O board RCNA, RMBP, RETA, RECA, REPL, RRIA (RMIO) or RTAC Option module 2: RTAC, RAIO, RRIA or...

  • Page 28: Printed Circuit Boards

    Printed circuit boards The drive contains the following printed circuit boards as standard: • main circuit board (RINT) • motor control and I/O board (RMIO) • EMC filter board (RRFC) when EMC equipment is selected or varistor board (RVAR) otherwise •...

  • Page 29: 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 either in a cardboard box or in a plywood package. The package also contains: •...

  • Page 30: Example 1

    Example 1 1. To cut the box into two pieces, pull from the spots marked with arrows. 2. Remove the upper part of the box. 3. Remove the unit and other contents from the box. Pull Do not lift by the cover. Mechanical installation...

  • Page 31: Example 2

    Example 2 1. Cut the straps. 2. Remove the outer box and sleeve. 3. Remove the locking sheet and the screws that attach the unit to the bottom pallet. Mechanical installation...

  • Page 32: Checking The Delivery

    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 33: 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]. When mounting IP55 units above one another, leave 200 mm (7.9 in.) free space above and below the unit. 50 [2.0] 200 [7.9] 50 [2.0]...

  • Page 34: Mounting The Drive On The Wall

    Mounting the drive on the wall Units without vibration dampers 1. Mark the locations for the four holes. The mounting points are shown in Dimensional drawings. In frame sizes R2 to R5 (IP21, UL type 1), use the mounting template cut from the package. 2.

  • Page 35: Cabinet Installation

    Cabinet installation For better cooling, it is recommended to remove the front cover if the unit is installed into a cabinet. The required distance between parallel units is five millimetres (0.2 in.) in installations without the front cover. The cooling air entering the unit must not exceed +40 °C (+104 °F).

  • Page 36: Unit Above Another

    Unit above another Lead the out-coming cooling air away from the unit above. Example max.+40 °C (+104 °F) Mechanical installation...

  • Page 37: 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 38: 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 39: Requirements Table

    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-driven end) motor bearings and ABB common mode filters are required. Ignoring the requirements or improper installation may shorten motor life or damage the motor bearings and voids the warranty.
  • Page 40 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 41 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 42 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 43: Permanent Magnet Motor

    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 44: Supply Connection

    Supply connection Disconnecting device Install a hand-operated input disconnecting device 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. 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: •...

  • Page 45: Thermal Overload And Short-Circuit Protection

    Thermal overload and short-circuit protection Thermal overload protection of the drive and the input and motor cables 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.

  • Page 46: Protection Against Short-Circuit Inside The Drive Or In The Supply Cable

    ABB with the ACS800 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.

  • Page 47: 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 firmware manual.

  • Page 48: Prevention Of Unexpected Start-Up (Option +Q950)

    Prevention of unexpected start-up (option +Q950) The drive 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 49: 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 an uncontrolled stop in accordance with category 0 of EN 60204-1and Prevention of unexpected start-up of EN 1037.

  • Page 50: Safe Torque Off Circuit Diagram

    Safe torque off circuit diagram 3AUA0000072271 Planning the electrical installation...

  • Page 51: 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 52: 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 53: Motor Cable Shield

    Motor cable shield If the motor cable shield is used as the sole protective earth conductor of the motor, ensure that the conductivity of the shield is sufficient. See section General rules above, or IEC 61439-1. To effectively suppress radiated and conducted radio- frequency emissions, the shield conductivity must be at least 1/10 of the phase conductor conductivity.

  • Page 54: 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 or harmonic filters to the motor cables (between the drive and the motor).

  • Page 55: 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 56: 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 57: 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 58: 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 59: 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 60 Planning the electrical installation...

  • Page 61: 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 62: 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 63: Connecting The Power Cables

    Connecting the power cables Diagram Drive OUTPUT INPUT UDC+ V1 W1 U2 V2 W2 (PE) (PE) External brake For alternatives, see resistor Planning the electrical Motor installation: Disconnecting device 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 64: 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 R2, R3 0.39 R4, R5 0.63 1.10 Allowed wire sizes, tightening torques Technical data: Cable entries. Wall installed units (European version) Power cable installation procedure 1.
  • Page 65 Connection box (IP21) Fastening hooks Back plate Fastening screws 360 degrees grounding clamp Grommet Motor cable entry Input cable entry Brake resistor cable entry Control cable entry Bottom plate Fasten the control cables between these plates with cable Cover ties Frame sizes R2 to R4 UDC+ R+ UDC...
  • Page 66 Frame size R5 UDC+ UDC- Electrical installation...
  • Page 67 Frame size 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 Connection plate insulating tape or fastening screws shrink tubing.

  • Page 68: Wall Installed Units (Us Version)

    Wall installed units (US version) 1. Remove the front cover (in frame size R6 the lower front cover) by releasing the retaining clip with a screw driver and lifting the cover from the bottom outwards. 2. Make the cable entry holes in the gland box by breaking off the suitable knock-out plates with a screw driver.

  • Page 69: Warning Sticker

    Wire size Compression lug Crimping tool MCM/AWG Manufacturer Type Manufacturer Type No. of crimps Burndy YAV6C-L2 Burndy MY29-3 Ilsco CCL-6-38 Ilsco ILC-10 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...

  • Page 70: Cabinet Installation (Ip21, Ul Type 1)

    Cabinet installation (IP21, UL type 1) The drive can be installed in a cabinet without the connection box and front cover. It is recommended: • to ground the cable shield 360 degrees at the cabinet entry • to lead the cable unstripped as close to the terminals as possible. Secure the cables mechanically.

  • Page 71: Frame Size R6

    Frame size R6 Cover the power cable terminals as follows: 1. Cut holes for the installed cables into the clear plastic shroud in cable lug installations. 2. Press the shroud onto the terminals. View of cable terminal installation Removal of the shroud by lifting up with a screw driver from the corner: Electrical installation...

  • Page 72: 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 73 Frame sizes R5 and R6 View of frame size R6 Control panel Option module 2 Option module 1 DDCS communication option module 3: RDCO Place the warning sticker here Control cable Detachable connection terminals (pull up) grounding: see section Terminal for optional Prevention of unexpected degrees start-up (+Q950) or optional Safe torque off grounding...

  • Page 74: 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 75: 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 As short as possible Note 1: If the encoder is of unisolated type, ground the encoder cable at the drive end only.

  • Page 76: 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 77: What This Chapter Contains

    Installation of the AGPS board (Prevention of unexpected start-up, +Q950) What this chapter contains This chapter describes electrical installation of the optional Prevention of unexpected start-up function (+Q950) of the drive, and gives instructions for starting up, validating and using the function. Prevention of unexpected start-up (+Q950) The optional Prevention of unexpected start-up function includes an external AGPS board which is connected to the drive and an external power supply.
  • Page 78 The following figure shows how the external AGPS board is connected to the drive. The cable (length 3 m [10 ft]) is delivered with the AGPS board. 3 m (10 ft) • page for location of terminal X41 of the drive •...
  • Page 79 Connect the AGPS board as follows: • Remove the enclosure cover by undoing the fixing screws (1). • Ground the unit via the bottom plate of the enclosure or via terminal X1:1 of the AGPS board. • Connect the cable delivered with the kit between terminal X2 of the AGPS board (2) and drive terminal X41.

  • Page 80: Circuit Diagram

    Circuit diagram This circuit diagram shows how the AGPS-11 kit is installed. 3AFE00374994 Installation of the AGPS board (Prevention of unexpected start-up, +Q950)

  • Page 81: Start-Up And Validation

    Start-up and validation Action Follow the safety instructions, see section Safety instructions on page 5. 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 82 Installation of the AGPS board (Prevention of unexpected start-up, +Q950)

  • Page 83: 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 external ASTO board, which is connected to the drive and an external power supply.
  • Page 84 The following figure shows how the external ASTO board is connected the drive. The cable (length 3 m [10 ft]) is delivered with the ASTO board. 3 m (10 ft) • page for location of terminal X41 of the drive •...
  • Page 85 Connect the ASTO board as follows: • Remove the cover of the enclosed ASTO unit by undoing the fixing screws (1). • Ground the ASTO unit via the bottom plate of the enclosure or via terminal X1:2 or X1:4 of the ASTO board. •...

  • Page 86: 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 50. 3AUA0000072542 Start-up and validation 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 87: 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 Option modules (Rxxx) may have identical terminal designations with the RMIO board.

  • Page 88: 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 control macros and programs, see the appropriate firmware manual. RMIO RMIO VREF- Reference voltage -10 V DC, 1 kohm <...

  • Page 89: 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 control macros and programs, see the appropriate firmware manual. RMIO RMIO VREF-...

  • Page 90: 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, = 200 kohm). The analogue inputs are galvanically isolated as a group.

  • Page 91: Relay Outputs

    Maximum continuous current 2 A rms Insulation test voltage 4 kV AC, 1 minute DDCS fibre optic link With optional communication adapter module RDCO. Protocol: DDCS (ABB Distributed Drives Communication System) 24 V DC power input Voltage 24 V DC ± 10%...
  • Page 92 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 93: 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 94 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 95: Start-Up And Use

    Start-up and use What this chapter contains This chapter describes the start-up procedure and use of the drive. Startup procedure 1. Ensure that the installation of the drive has been checked according to the checklist in chapter Installation checklist, and that the motor and driven equipment are ready for start.
  • Page 96 Start-up and use...

  • Page 97: Maintenance

    IP21 units when included Every 6 years Cooling fan replacement See Fan. Every 10 years Frame size R4 and up: See Capacitors. capacitor replacement Consult your local ABB Service representative for more details on the maintenance. On the Internet, go to http://www.abb.com/drives. Maintenance...

  • Page 98: 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 99: Fan Replacement (R4)

    Fan replacement (R4) 1. Loosen the screws that fasten the fan mounting plate to the frame. 2. Push the fan mounting plate to the left and pull it out. 3. Disconnect the fan power cable. 4. Undo the screws that fasten the fan to the fan mounting plate. 5.

  • Page 100: Fan Replacement (R5)

    Fan replacement (R5) 1. Undo the fastening screw. 2. Open the swing-out frame and disconnect the cable. 3. Undo the fastening screws of the fan. 4. Install the new fan in reverse order. Maintenance...

  • Page 101: Fan Replacement (R6)

    Fan replacement (R6) Note: In -0205-3 and 0255-5 units, access the fan through the opening in the support frame of the cable connection box. 1. Remove the screw attaching the fan casing and let the casing lean down against the limiters. 2.

  • Page 102: Additional Fan

    Additional fan There is an additional cooling fan in all IP55 units and most IP21 units. However, there is no additional fan in the following IP21 units: -0003-3, -0004-3, -0005-3, -0004-5, -0005-5 and -0006-5. The following IP55 units have two additional fans: -0205-3 and -0255-5.

  • Page 103: Capacitors

    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 for frame size R4 and up are available from ABB. Do not use other than ABB specified spare parts.
  • Page 104 Maintenance...

  • Page 105: 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 ACS800-01 with 50 Hz and 60 Hz supplies are given below. The symbols are described below the table.
  • Page 106 ACS800-01 size Nominal Light-overload Heavy-duty use Frame Air flow Heat overload ratings size dissipation cont.max cont.max Three-phase supply voltage 380 V, 400 V or 415 V -0003-3 -0004-3 -0005-3 10.8 -0006-3 10.9 13.8 10.2 -0009-3 13.9 17.6 12.7 -0011-3 -0016-3 -0020-3 -0025-3 18.5...

  • Page 107: Symbols

    ACS800-01 size Nominal Light-overload Heavy-duty use Frame Air flow Heat overload ratings size dissipation cont.max cont.max Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V -0011-7 11.5 -0016-7 -0020-7 18.5 -0025-7 18.5 -0030-7 18.5 -0040-7 -0050-7...

  • Page 108: Derating

    Note 3: Use the DriveSize PC tool for a more accurate dimensioning if the ambient temperature is below 40 °C (104 °F) or the drive is loaded cyclically. Derating The load capacity (current and power) decreases if the installation site altitude exceeds 1000 metres (3300 ft), or if the ambient temperature exceeds 40 °C (104 °F).
  • Page 109 ACS800-01 Input Fuse size current Manufacturer Type IEC size Three-phase supply voltage 208 V, 220 V, 230 V or 240 V -0001-2 ABB Control OFAF000H10 -0002-2 ABB Control OFAF000H10 -0003-2 ABB Control OFAF000H10 -0004-2 ABB Control OFAF000H16 -0005-2 ABB Control...

  • Page 110: Frame Sizes R5 And R6

    Frame sizes R5 and R6 Choose between gG and aR fuses according to the table under Quick guide for selecting between gG and aR fuses on page 114, 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.

  • Page 111: Fuse Tables For Frame Sizes R5 And R6

    2 · The calculated short-circuit current 2.7 kA is higher than the minimum short-circuit current of the drive gG fuse type OFAF00H160 (2400 A). -> The 500 V gG fuse (ABB Control OFAF00H160) can be used. Fuse tables for frame sizes R5 and R6...
  • Page 112 Manufacturer Type IEC size Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V -0050-5 1050 34500 ABB Control OFAF000H80 -0060-5 1480 63600 ABB Control OFAF000H100 -0070-5 1940 103000...

  • Page 113: Ultrarapid (Ar) Fuses

    Ultrarapid (aR) fuses ACS800-01 size Input Min. Fuse current short- circuit current Manufacturer Type IEC size Three-phase supply voltage 208 V, 220 V, 230 V or 240 V -0025-2 4650 Bussmann 170M1567D DIN000 -0030-2 8500 Bussmann 170M1568D DIN000 -0040-2 8500 Bussmann 170M1569D DIN000...

  • Page 114: Quick Guide For Selecting Between Gg And Ar Fuses

    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 fulfil the minimum requirements for the proper operation of the fuse. ACS800-01 size Cable type Supply transformer minimum apparent power S...
  • Page 115 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. Technical data...

  • Page 116: 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 (86 °F), PVC insulation, surface temperature 70 °C (158 °F) (EN 60204-1 and IEC 60364-5-52:2001).

  • Page 117: Cable Entries

    Cable entries Brake resistor, mains and motor cable terminal sizes (per phase), accepted cable diameters and tightening torques are given below Frame U1, V1, W1, U2, V2, W2, R+, R Earthing PE size Wire size Max. cable Ø Cable Ø Tightening Wire size Tightening...

  • Page 118: Nema Data

    NEMA data Ratings The NEMA ratings for the ACS800-U1 with 60 Hz supplies are given below. The symbols are described below the table. For sizing, derating and 50 Hz supplies, see IEC data on page 105. ACS800-U1 size Normal use Heavy-duty use Frame Air flow...

  • Page 119: Symbols

    ACS800-U1 size Normal use Heavy-duty use Frame Air flow Heat size dissipation /min BTU/Hr Three-phase supply voltage 525 V, 575 V, 600 V -0011-7 11.5 1050 -0016-7 1200 -0020-7 15/20 1550 -0025-7 1850 -0030-7 25/30 2100 -0040-7 2400 -0050-7 2900 -0060-7 3450 -0070-7...

  • Page 120: Fuses

    Fuses UL class T fuses for branch circuit protection 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 0.5 seconds for units of frame sizes R2 to R4 and 0.1 seconds for units of frame sizes R5 and R6.

  • Page 121: Cable Types

    ACS800-U1 type Frame size Input Fuse current Manufacturer Type UL class Three-phase supply voltage 525 V, 575 V, 600 V -0011-7 Bussmann JJS-20 -0016-7 Bussmann JJS-20 -0020-7 Bussmann JJS-30 -0025-7 Bussmann JJS-30 -0030-7 Bussmann JJS-45 -0040-7 Bussmann JJS-45 -0050-7 Bussmann JJS-70 -0060-7 Bussmann...

  • Page 122: Cable Entries

    Cable Entries Brake resistor, input and motor cable (per phase) terminal sizes, accepted cable diameters and tightening torques are given below Frame U1, V1, W1, U2, V2, W2, R+, R Earthing PE size Wire size Knock-out hole Ø Tightening Wire size Tightening (UL type 1) torque...

  • Page 123: Input Power Connection

    Input power connection Voltage (U 208/220/230/240 V AC 3-phase ± 10% for 230 V AC units 380/400/415 V AC 3-phase ± 10% for 400 V AC units 380/400/415/440/460/480/500 V AC 3-phase ± 10% for 500 V AC units 525/550/575/600/660/690 V AC 3-phase ± 10% for 690 V AC units Short-circuit withstand Maximum allowable prospective short-circuit current is 65 kA when protected by fuses strength (IEC 60439-1)

  • 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) and IP55 (UL type 12). Without the connection box and front cover, the unit must be protected against contact according to IP2x [see chapter Electrical installation: Cabinet installation (IP21, UL type...

  • Page 125: Ambient Conditions

    Ambient conditions Environmental limits for the drive are given below. The drive is to be used in a heated, indoor, controlled environment. Operation Storage Transportation installed for stationary use in the protective package in the protective package Installation site altitude 0 to 4000 m (13123 ft) above sea level [above 1000 m (3281 ft), see section...

  • Page 126: Materials

    IEC 62635 guidelines. To aid recycling, plastic parts are marked with an appropriate identification code. Contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recyclers. End of life treatment must follow international and local regulations.

  • Page 127: Ce Marking

    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. The CE marking also verifies that the drive, in regard to its safety functions (such as Safe torque off), conforms with the Machinery Directive as a safety component.

  • Page 128: First Environment (Drive Of Category C2)

    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. First environment (drive of category C2) The drive complies with the standard with the following provisions: 1.

  • Page 129: 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 WARNING! A drive of category C4 is not intended to be used on a low-voltage public network which supplies domestic premises.

  • Page 130: Ul/Csa Markings

    Code (NEC). See the firmware manual for setting. Default setting is off, must be activated at start-up. • 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).

  • Page 131: Dimensional Drawings

    Dimensional drawings Dimensional drawings of the ACS800-01 are shown below. The dimensions are given in millimetres and [inches]. Dimensional drawings...

  • Page 132: Frame Size R2 (Ip21, Ul Type 1)

    Frame size R2 (IP21, UL type 1) Dimensional drawings...

  • Page 133: Frame Size R2 (Ip55, Ul Type 12)

    Frame size R2 (IP55, UL type 12) Dimensional drawings...

  • Page 134: Frame Size R3 (Ip21, Ul Type 1)

    Frame size R3 (IP21, UL type 1) Dimensional drawings...

  • Page 135: Frame Size R3 (Ip55, Ul Type 12)

    Frame size R3 (IP55, UL type 12) Dimensional drawings...

  • Page 136: Frame Size R4 (Ip21, Ul Type 1)

    Frame size R4 (IP21, UL type 1) Dimensional drawings...

  • Page 137: Frame Size R4 (Ip55, Ul Type 12)

    Frame size R4 (IP55, UL type 12) Dimensional drawings...

  • Page 138: Frame Size R5 (Ip21, Ul Type 1)

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

  • Page 139: Frame Size R5 (Ip55, Ul Type 12)

    Frame size R5 (IP55, UL type 12) Dimensional drawings...

  • Page 140: Frame Size R6 (Ip21, Ul Type 1)

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

  • Page 141: Frame Size R6 (Ip21, Ul Type 1), -205-3 And -255-5 Units

    Frame size R6 (IP21, UL type 1), -205-3 and -255-5 units Note: Only measurements that differ from those of the standard Frame size R6 (IP21, UL type 1) are given below. Dimensional drawings...

  • Page 142: Frame Size R6 (Ip55, Ul Type 12)

    Frame size R6 (IP55, UL type 12) For types -0205 and -0255-5, see page 143. Dimensional drawings...

  • Page 143: Frame Size R6 (Ip55, Ul Type 12) -0205-3 And -0255-5 Units

    Frame size R6 (IP55, UL type 12) -0205-3 and -0255-5 units Dimensional drawings...

  • Page 144: Dimensional Drawings (Usa)

    Dimensional drawings (USA) Dimensional drawings of the ACS800-U1 are shown below. The dimensions are given in millimetres and [inches]. Dimensional drawings...

  • Page 145: Frame Size R2 (Ul Type 1, Ip21)

    Frame size R2 (UL type 1, IP21) Dimensional drawings...

  • Page 146: Frame Size R2 (Ul Type 12, Ip55)

    Frame size R2 (UL type 12, IP55) Dimensional drawings...

  • Page 147: Frame Size R3 (Ul Type 1, Ip21)

    Frame size R3 (UL type 1, IP21) Dimensional drawings...

  • Page 148: Frame Size R3 (Ul Type 12, Ip55)

    Frame size R3 (UL type 12, IP55) Dimensional drawings...

  • Page 149: Frame Size R4 (Ul Type 1, Ip21)

    Frame size R4 (UL type 1, IP21) Dimensional drawings...

  • Page 150: Frame Size R4 (Ul Type 12, Ip55)

    Frame size R4 (UL type 12, IP55) Dimensional drawings...

  • Page 151: Frame Size R5 (Ul Type 1, Ip21)

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

  • Page 152: Frame Size R5 (Ul Type 12, Ip55)

    Frame size R5 (UL type 12, IP55) Dimensional drawings...

  • Page 153: Frame Size R6 (Ul Type 1, Ip21)

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

  • Page 154: Frame Size R6 (Ul Type 1, Ip21) -0205-3 And -0255-5 Units

    Frame size R6 (UL type 1, IP21) -0205-3 and -0255-5 units Note: Only measurements that differ from those of the standard Frame size R6 (UL type 1, IP21) are given below. Dimensional drawings...

  • Page 155: Frame Size R6 (Ul Type 12, Ip55)

    Frame size R6 (UL type 12, IP55) For types -0205 and -0255-5, see page 156. Dimensional drawings...

  • Page 156: Frame Size R6 (Ul Type 12, Ip55) -0205-3 And -0255-5 Units

    Frame size R6 (UL type 12, IP55) -0205-3 and -0255-5 units Dimensional drawings...

  • Page 157: Agps Board (Option +Q950)

    AGPS board (option +Q950) Dimensional drawings...

  • Page 158: Asto Board With Enclosure (Option +Q967)

    ASTO board with enclosure (option +Q967) Dimensional drawings...

  • Page 159: Resistor Braking

    Resistor braking What this chapter contains This chapter describes how to select, protect and wire brake choppers and resistors. The chapter also contains the technical data. Availability of brake choppers and resistors for the ACS800 Frame R2 and R3 drives and 690 V units of frame size R4 have a built-in brake chopper as standard equipment.

  • Page 160: Optional Brake Chopper And Resistor(S) For The Acs800-01/U1

    Note: 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.
  • Page 161 ACS800-01 type Braking power Brake resistor(s) of the chopper ACS800-U1 type and the drive Type brcont Rcont (kW) (ohm) (kJ) (kW) 400 V units -0003-3 SACE08RE44 -0004-3 SACE08RE44 -0005-3 SACE08RE44 -0006-3 SACE08RE44 -0009-3 SACE08RE44 -0011-3 SACE15RE22 -0016-3 SACE15RE22 -0020-3 SACE15RE22 -0025-3 SACE15RE13 -0030-3...

  • Page 162: Resistor Installation And Wiring

    ACS800-01 type Braking power Brake resistor(s) of the chopper ACS800-U1 type and the drive Type brcont Rcont (kW) (ohm) (kJ) (kW) 690 V units -0011-7 SACE08RE44 -0016-7 SACE08RE44 -0020-7 SACE08RE44 -0025-7 SACE08RE44 -0030-7 SACE15RE22 -0040-7 22/33 SACE15RE22 -0050-7 SACE15RE13 -0060-7 SACE15RE13 -0070-7 SAFUR90F575...

  • Page 163: Protection Of Frame Sizes R2 To R5 (Acs800-01/U1)

    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.

  • Page 164: Brake Circuit Commissioning

    With Standard Control Program, wire the thermal switch as shown below. By default, the drive will stop by coasting when the switch opens. RMIO:X22 or X2: X22 +24VD Thermal switch +24VD (standard in ABB re- DGND1  sistors) DGND2 DIIL For other control programs, the thermal switch may be wired to a different digital input.

  • Page 165: External +24 V Dc Power Supply For The Rmio Board Via Terminal X34

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

  • Page 166: Connecting +24 V Dc External Power Supply

    Connecting +24 V DC external power supply 1. Break off the tab covering the +24 V DC power input connector with pliers. 2. Lift the connector upwards. 3. Disconnect the wires from the connector (keep the connector for later use). 4.
  • Page 167 RMIO board RMIO board Connection of a two-way Connection of a three-way connector connector External +24 V DC power supply for the RMIO board via terminal X34...
  • Page 168 External +24 V DC power supply for the RMIO board via terminal X34...

  • Page 169: Rdco-01/02/03/04 Ddcs Communication Option Modules

    RDCO-01/02/03/04 DDCS communication option modules What this chapter contains This chapter contains a description of the RDCO-0x DDCS communication option modules connections and the technical specifications of the RDCO-0x modules. Overview The RDCO-0x DDCS Communication options are add-on modules for the •...

  • Page 170: Delivery Check

    Delivery check The option package contains: • RDCO-0x module • Two screws (M3×8) • This document. Module layout CH 0 CH 1 Fiber optic channels Fixing screws CH 2 CHGND CH 3 Installation WARNING! All electrical installation and maintenance work on the drive should be carried out by qualified electricians only.

  • Page 171: Installation Procedure

    WARNING! Handle the fiber optic cables with care. The maximum long term tensile load is 1 N; the minimum short term bend radius is 35 mm. Do not touch the ends of the fibers with bare hands as the fiber is extremely sensitive to dirt. Use rubber grommets at cable entries to protect the cables.
  • Page 172 Electromagnetic emissions: EN 50081-2; CISPR 11 Dimensions (mm): RDCO-01/02/03/04 DDCS communication option modules...

  • Page 173: Further Information

    Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/searchchannels.
  • Page 174 Contact us www.abb.com/drives www.abb.com/drivespartners 3AFE64382101 Rev K (EN) 2013-06-27...

This manual is also suitable for:

Acs800-01 seriesAcs800-u1 seriesAcs800-01-0001-2Acs800-01-0002-2Acs800-01-0003-2Acs800-01-0004-2 ... Show all

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