ABB ACS800-04 Hardware Manual
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ABB ACS800-04 Hardware Manual

Acs800 series
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ACS800
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ACS800-04 and ACS800-04M Drive Modules (45 to 560 kW)
ACS800-U4 Drive Modules (60 to 600 HP)

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Summary of Contents for ABB ACS800-04

  • Page 1 ACS800 Hardware Manual ACS800-04 and ACS800-04M Drive Modules (45 to 560 kW) ACS800-U4 Drive Modules (60 to 600 HP)

  • Page 2: Acs800 Single Drive Manuals

    3AFE68599954 (English) ACS800-02/U2 Hardware Manual 90 to 500 kW (125 to 600 HP) 3AFE64567373 (English) ACS800-04/U4 Hardware Manual 0.55 to 160 kW (0.75 to 200 HP) 3AFE68372984 (English) ACS800-04/04M/U4 Hardware Manual 45 to 560 kW (60 to 600 HP) 3AFE64671006 (English)
  • Page 3 ACS800-04 and ACS800-04M Drive Modules 45 to 560 kW ACS800-U4 Drive Modules 60 to 600 HP Hardware Manual 3AFE64671006 Rev F EN EFFECTIVE: 15.6.2007 © 2007 ABB Oy. All Rights Reserved.

  • Page 5: Safety Instructions

    To which products this chapter applies This chapter applies to the ACS800-01/U1, ACS800-11/U11, ACS800-31/U31, ACS800-02/U2 and ACS800-04/04M/U4 of frame sizes R7 and R8. Use of warnings and notes There are two types of safety instructions throughout this manual: warnings and notes.

  • Page 6: Installation And Maintenance Work

    Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V) may be present on the terminals of relay outputs RO1 to RO3 or on the optional AGPS board (Prevention of Unexpected Start, ACS800-01/U1, ACS800-04/ 04M, ACS800-11/U11, ACS800-31/U31).

  • Page 7: Grounding

    In addition, connect the cable shields to protective earth (PE) in order to meet safety regulations. ACS800-04 (45 to 560 kW) and ACS800-02 in first environment: make a 360° high frequency grounding of motor cable entries at the cabinet lead-through.

  • Page 8: Mechanical Installation And Maintenance

    Do not lift the unit by the front cover. Place the unit only on its back. ACS800-02, ACS800-04: The drive is heavy. Lift the drive by the lifting lugs only. Do not tilt the unit. The unit will overturn from a tilt of about 6 degrees.

  • 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. Installation and maintenance work WARNING! Do not work on the drive when the permanent magnet motor is rotating. Also, when the supply power is switched off and the inverter is stopped, a rotating permanent magnet motor feeds power to the intermediate circuit of the drive and the supply connections become live.
  • Page 12 Safety instructions...

  • Page 13: Table Of Contents

    Providing feedback on ABB Drives manuals ........
  • Page 14 Disconnecting device (disconnecting means) ........40 ACS800-01, ACS800-U1, ACS800-11, ACS800-U11, ACS800-31, ACS800-U31, ACS800-02 and ACS800-U2 without enclosure extension, ACS800-04, ACS800-U4 .40 ACS800-02 and ACS800-U2 with enclosure extension, ACS800-07 and ACS800-U7 .40 EU .
  • Page 15 Selecting the power cables ............46 General rules .
  • Page 16 Motor control and I/O board (RMIO) What this chapter contains ............65 To which products this chapter applies .
  • Page 17 Technical data What this chapter contains ............83 IEC data .
  • Page 18 R8 (ACS800-02, ACS800-04, ACS800-07) ........

  • Page 19: About This Manual

    Common chapters for several products Chapters Planning the electrical installation, Motor control and I/O board (RMIO) Resistor braking apply to the ACS800-01/U1, ACS800-02/U2, ACS800-04/04M/U4 and ACS800-07/U7 types up to -0610-x. Safety instructions apply to the ACS800-01/ U1, ACS800-02/U2 and ACS800-04/04M/U4.

  • Page 20: Contents

    The chapter also contains technical data. Other related manuals Refer to ACS800-04/04M/U4 Cabinet Installation [3AFE68360323 (English)] for information concerning the drive module such as • dimensional drawings of the drive module •...

  • Page 21: Product And Service Inquiries

    Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type code and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/drives...

  • Page 22: Providing Feedback On Abb Drives Manuals

    Providing feedback on ABB Drives manuals Your comments on our manuals are welcome. Go to www.abb.com/drives, then select successively Drives – Document Library – Manuals feedback form on the right pane. About this manual...

  • Page 23: The Acs800-04/U4 And Acs800-04M

    This chapter describes the construction and operating principle of the drive in short. The ACS800-04/U4 The ACS800-04/U4 is an IP 00 drive module for controlling AC motors. It is to be installed into a cabinet by the customer with base or wall fastening. The input cable terminals are located at the top of the unit whereas the motor cable terminals are located at the left- or right-hand side of the unit.

  • Page 24: The Acs800-04M

    The ACS800-04M The ACS800-04M is delivered as non-pre-assembled kits, which provide more alternatives in assembling the units than the basic ACS800-04. Example configurations Frame size R7 Motor and brake busbars on the Output busbars on the short Motor and brake busbars on the...

  • Page 25: Type Designation Label

    The type designation label is located on the front cover and the serial number label inside the unit. Example labels are shown below. The ACS800-04/U4 and ACS800-04M...

  • 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 (e.g. ACS800-04- 0170-5). The optional selections are given thereafter, separated by plus signs (e.g. +E202). The main selections are described below. Not all selections are available for all types.
  • Page 27 P901 coated boards Safety features Q950 Prevention of Unexpected Start, 500 mm (19.68 in.) cable outside the drive module in frame size R7, 600 mm (23.62 in.) cable outside the drive module in frame size R8. The ACS800-04/U4 and ACS800-04M...

  • Page 28: Control Interfaces

    RCAN, RCNA, RMBP, RETA, RRIA or (RMIO) RTAC Optional module 2: RTAC, RAIO, RRIA External control via or RDIO analogue/digital inputs and outputs DDCS communication option module: RDCO-01, RDCO-02 or RDCO-03 Input power Output power Brake chopper (optional) R- UDC+ UDC- The ACS800-04/U4 and ACS800-04M...

  • Page 29: Connections Of The Drive Control Unit (Rdcu) In Frame Sizes R7 And R8

    AC voltage to DC voltage capacitor bank energy storage which stabilizes the intermediate circuit DC voltage six-pulse IGBT inverter converts the DC voltage to AC voltage and vice versa. The motor operation is controlled by switching the IGBTs. The ACS800-04/U4 and ACS800-04M...

  • Page 30: Printed Circuit Boards

    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. The ACS800-04/U4 and ACS800-04M...

  • Page 31: Mechanical Installation

    This chapter describes the mechanical installation of the drive cabinet generally. Follow the specific instructions given by the panel builder. For the mechanical assembly and dimensional drawings of the drive module, refer to ACS800-04/04M/ U4 Cabinet Installation [3AFE68360323 (English)]. Before installation...

  • Page 32: Cable Channel In The Floor Below The Cabinet

    Cable channel in the floor below the cabinet When a cable channel is constructed below the cabinet, ensure that cabinet weight lies on the sections which the floor carries. Example cabinet frame viewed from above Example cabinet: side view Cables Prevent the cooling air flow from the cable channel to the cabinet by bottom plates.

  • Page 33: 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 34 3. Check that the motor voltage rating meets the application requirements: If the drive is equipped … and … … then the motor voltage with … rating should be … diode supply no resistor braking is in use ACS800-01, -U1, -02, -U2, frequent or long term brake cycles will ACeq1 -04, -04M, -U4 -07, -U7...

  • Page 35: 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 36: 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. The motor manufacturer should be consulted regarding the construction of the motor insulation and additional requirements for explosion-safe (EX) motors.
  • Page 37 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 38 For motors with higher rated output than what is stated for the particular frame size in EN 50347 (2001) and for IP 23 motors, the requirements of ABB random-wound motor series M3AA, M3AP, M3BP are given below. For other motor types, see the Requirements table above.

  • Page 39: Permanent Magnet Synchronous Motor

    Note 8: Calculating the rise time and the peak line-to-line voltage The peak line-to-line voltage at the motor terminals generated by the drive as well as the voltage rise time depend on the cable length. The requirements for the motor insulation system given in the table are “worst case”...

  • Page 40: Supply Connection

    Disconnecting device (disconnecting means) ACS800-01, ACS800-U1, ACS800-11, ACS800-U11, ACS800-31, ACS800-U31, ACS800-02 and ACS800-U2 without enclosure extension, ACS800-04, ACS800-U4 Install a hand-operated input disconnecting device (disconnecting means) between the AC power source and the drive. The disconnecting device must be of a type that can be locked to the open position for installation and maintenance work.

  • Page 41: 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 42: Protection Against Short-Circuit Inside The Drive Or In The Supply Cable

    Input cable module ACS800-02 See footnotes 1) and ACS800-U2+0C111 ACS800-11 ACS800-U11 ACS800-31 ACS800-U31 ACS800-04 ACS800-U4 DRIVE IS EQUIPPED WITH INPUT FUSES ACS800-02+C111 Protect the input cable Distribution with fuses or a circuit ACS800-U2 board Input cable Drive...

  • Page 43: Ground Fault Protection

    2) Circuit breakers which have been tested by 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. The protective characteristics of circuit breakers depend on the type, construction and settings of the breakers.

  • Page 44: Power-Loss Ride-Through Function

    Power-loss ride-through function The power-loss ride-through function is activated when parameter 20.06 UNDERVOLTAGE CTRL is set to ON (default in Standard Control Program). ACS800-07/U7 units without line contactor The power-loss ride-through funtion is not in use. ACS800-07/U7 units with line contactor (+F250) The power-loss ride-through funtion is enabled by connecting RMIO board terminals X22:8 and X22:11 with a jumper.

  • Page 45: Prevention Of Unexpected Start

    EN 60204-1: 1997. • indicating lamp; on = starting the drive is prevented, off = drive is operative. • ACS800-01/U1, ACS800-04/U4, ACS800-11/U11, ACS800-31/U31: safety relay (type BD5935 has been approved by ABB) For connections to the drive, see chapter Installation of AGPS board (Prevention of Unexpedted Start, +Q950) or the circuit diagram delivered with the drive (ACS800- 07/U7).

  • Page 46: 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. ° • The cable must be rated for at least 70 C maximum permissible temperature of conductor in continuous use.

  • Page 47: 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 48: Additional Us Requirements

    Additional US requirements Type MC continuous corrugated aluminum 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 V AC cable is accepted for up to 500 V AC.

  • Page 49: Equipment Connected To The Motor Cable

    If there are power factor compensation capacitors in parallel with the three phase input of the drive: 1. Do not connect a high-power capacitor to the power line while the drive is connected. The connection will cause voltage transients that may trip or even damage the drive.

  • Page 50: 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 51: 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 52: 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 53: 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 54 Planning the electrical installation...

  • Page 55: Electrical Installation

    Electrical installation What this chapter contains This chapter instructs in the cabling of the drive. Warnings WARNING! Only qualified electricians are allowed to carry out the work described in this chapter. Follow the Safety instructions on the first pages of this manual. Ignoring the safety instructions can cause injury or death.

  • Page 56: It (Ungrounded) Systems

    (ungrounded systems). If the drive is equipped with EMC filter +E202, disconnect the filter before connecting the drive to an ungrounded system. For detailed instructions on how to do this, please contact your local ABB representative. WARNING! If a drive with EMC filter +E202 is installed on an IT system [an...

  • Page 57: Example Wiring Diagram

    Example wiring diagram The diagram below presents an example for the main wiring. Note that the diagram includes optional components which are not included in a basic delivery (marked *) and equipment not available as plus code options (marked **). Electrical installation...

  • Page 58: Power Cable Connection Diagram

    Power cable connection diagram Drive module OUTPUT INPUT UDC+ V1 W1 V2 W2 (PE) (PE) * For alternatives, see Planning the electrical External brake installation: Disconnecting resistor device (disconnecting means) Motor 1), 2) Grounding of the motor cable shield at the cabinet entry If shielded cable is used (not required but Ground the cable shield 360 degrees at the lead-through of the recommended) and the conductivity of the shield is...

  • Page 59: Grounding Of The Cable Shields

    Grounding of the cable shields To power terminals Example cable lead-through Strain relief Cable shield PE terminal of the cabinet or drive module EMC sleeve * Strip this part of the cable * Recommended Base plate for control Lead-through plate cables Strain relief...

  • Page 60: Fastening Us Cable Lugs

    Fastening US cable lugs Example mounting US cable lugs can be connected directly to the output busbars or to the terminals as follows. 1/2” bolt 1 3/4” Electrical installation...

  • Page 61: Connections Of The Rdcu

    Connections of the RDCU The RDCU drive control unit contains the RMIO board where the user’s control cables are connected. WARNING! Handle the fibre optic cables with care. When unplugging optic cables, always grab the connector, not the cable itself. Do not touch the ends of the fibres with bare hands as the fibre is extremely sensitive to dirt.

  • Page 62: Connecting The Control Cables To The Rmio Board

    Connecting the control cables to the RMIO board 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)]. Tighten the screws to secure the connection. Make a 360 degrees EMC grounding at the cabinet entry in first environment installations.

  • Page 63: Settings Of The Cooling Fan Transformer

    Settings of the cooling fan transformer The voltage transformer of the cooling fan is located at the top right-hand corner of the drive module. Remove the front cover for adjusting the settings and replace the cover after setting. Set to 220 V if the supply frequency is 60 Hz. Set to 230 V if the supply frequency is 50 Hz.

  • Page 64: Pulse Encoder Module Cabling

    Pulse encoder module cabling Clamp as close to the terminals as possible. Alternative to a) Note1: If the encoder is of unisolated As short as type, ground the encoder cable at the possible drive end only. If the encoder is Strain relief galvanically isolated from the motor with a cable tie...

  • Page 65: 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. To which products this chapter applies This chapter applies to ACS800 units which employ RMIO-01 board from revision J onwards and RMIO-02 board from revision H onwards.

  • Page 66: Note On External Power Supply

    Note on external power supply External +24 V power supply for the RMIO board is recommended if • the application requires a fast start after connecting the input power supply • fieldbus communication is required when the input power supply is disconnected. The RMIO board can be supplied from an external power source via terminal X23 or X34 or via both X23 and X34.

  • Page 67: 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 VDC, 1 kohm <...

  • Page 68: 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 69: Rmio Board Specifications

    RMIO board specifications Analogue inputs With Standard Control Program 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 = 200 kohm).

  • Page 70: Relay Outputs

    Maximum continuous current 2 A rms Insulation 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 71 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 72 Motor control and I/O board (RMIO)

  • Page 73: Maintenance

    Maintenance What this chapter contains This chapter contains preventive maintenance instructions. Safety WARNING! Read the Safety instructions on the first pages of this manual before performing any maintenance on the equipment. Ignoring the safety instructions can cause injury or death. WARNING! The drive module is heavy [frame size R7: 100 kg (220 lb), frame size R8: 200 kg (441 lb)].

  • Page 74: Maintenance Intervals

    Maintenance intervals If installed in an appropriate environment, the drive requires very little maintenance. This table lists the routine maintenance intervals recommended by ABB. Interval Maintenance Instruction Every year when stored Capacitor reforming See Reforming. Every 6 to 12 months Heatsink temperature check See Heatsink.

  • Page 75: Layout

    Layout The layout stickers of the drive are shown below. The stickers show all possible components. Not all of them are present in each delivery or described here. Components that need to be changed regularly are listed below: Designation Component Cooling fan Capacitors Code: 64572261...

  • Page 76: Heatsink

    See the appropriate ACS800 firmware manual for the actual signal which indicates the running time of the cooling fan. For resetting the running time signal after a fan replacement, please contact ABB. Replacement fans are available from ABB. Do not use other than ABB specified spare parts. Maintenance...

  • Page 77: Replacing The Fan (R7)

    Replacing the fan (R7) 1. Remove the front cover. 2. Disconnect the discharging resistor wire(s). 3. Remove the DC capacitor pack by undoing the red fixing screws and pulling the pack out. 4. Disconnect the fan supply wires (detachable connector). 5.

  • Page 78: Replacing The Fan (R8)

    Replacing the fan (R8) 1. Remove the front cover. 2. Disconnect the fan capacitor and power supply wires. 3. Undo the red fastening screws of the plastic side cover of the fan. Shift the cover to the right to free its right-hand edge and lift the cover off. 4.

  • Page 79: Capacitors

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

  • Page 80: Replacing The Capacitor Pack (R8)

    Replacing the capacitor pack (R8) 1. Remove the front cover. Remove the profiled side plate. 2. Disconnect the discharging resistor wires. 3. Undo the fastening screws. 4. Lift the capacitor pack out. 5. Install the new capacitor pack in reverse order to the above. At the rear side (view from below) 2 pcs in...

  • Page 81: Replacing The Drive Module

    Replacing the drive module • Disconnect the input power cable from the module. • Disconnect the power supply cable and the fibre optic cables from the RMIO board and coil them on the top of the converter module. • Disconnect the busbars outside the module. •...

  • Page 82: Leds

    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. Control panel mounting platform Drive in fault state Green The main + 24 V power supply for the control panel and the RMIO board is OK.

  • Page 83: Technical Data

    CE and other markings, and warranty policy. IEC data Ratings The IEC ratings for the ACS800-04 with 50 Hz and 60 Hz supplies are given below. The symbols are described below the table. ACS800-04 Nominal ratings...
  • Page 84 ACS800-04 Nominal ratings Light-overload use Heavy-duty use Frame Air flow Heat overload size size dissipation cont.max cont.max Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V -0170-5 3000 -0210-5 3800 -0260-5...

  • Page 85: Symbols

    Symbols Nominal ratings continuous rms output current. No overload capability at 40 °C. 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 34 motors at the nominal voltage, cont.max 230 V, 400 V, 500 V or 690 V.

  • Page 86: Fuses

    = transformer impedance (%) = transformer rated voltage (V) = nominal apparent power of the transformer (kVA) = cable reactance (ohm). Calculation example Drive: • ACS800-04-0260-3 • supply voltage U = 410 V Transformer: • rated power S = 3000 kVA •...

  • Page 87: Fuse Tables

    2 · The calculated short-circuit current 9.7 kA is higher than the minimum short-circuit current of the drive gG fuse type OFAF3H500 (8280 A). -> The 500 V gG fuse (ABB Control OFAF3H500) can be used. Fuse tables gG fuses...
  • Page 88 ACS800-04 Input Min. short- Fuse size current circuit current Manufacturer Type IEC size Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V -0170-5 3820 550 000 ABB Control OFAF1H250...

  • Page 89: Ultrarapid (Ar) Fuses

    Ultrarapid (aR) fuses ACS800-04 Input Min. short- Fuse size current circuit current Manufacturer Type DIN 43620 Size Three-phase supply voltage 208 V, 220 V, 230 V or 240 V -0080-2 1810 105 000 Bussmann 170M3819 DIN1* -0100-2 2210 145 000...
  • Page 90 Ultrarapid (aR) fuses ACS800-04 Input Min. short- Fuse size current circuit current Manufacturer Type DIN 43620 Size s value for -7 units at 660 V minimum short-circuit current of the installation Note 1: See also Planning the electrical installation: Thermal overload and short-circuit protection.

  • Page 91: 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. ACS800-04 size Cable type Supply transformer minimum apparent power S...

  • Page 92: Cable Types

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

  • Page 93: Cable Entries

    Cable entries Mains, motor and brake resistor cable terminal sizes (per phase), maximum accepted cable and tightening torques are given below. Frame U1, V1, W1, U2, V2, W2, UDC+/R+, UDC-, R- Earthing PE size Number of holes per Max. cable Screw Tightening Screw...

  • Page 94: Nema Data

    NEMA data Ratings The NEMA ratings for the ACS800-U4 and ACS800-04 with 60 Hz supplies are given below. The symbols are described below the table. For sizing, derating and 50 Hz supplies, see data. ACS800-U4 size Normal use Heavy-duty use...

  • Page 95: Symbols

    50% overload is allowed for one minute every five minutes if ambient temperature is less than 30 °C (86 °F). 40% overload is allowed if ambient temperature is 40 °C (104 °F). available if ambient temperature is less than 30 °C (86 °F). If ambient temperature is 40 °C (104 °F), I is 704 A.

  • Page 96: Ul Class T And L Fuses

    UL class T and L fuses ACS800-U4 type Input Fuse current Manufacturer Type UL class Three-phase supply voltage 208 V, 220 V, 230 V, 240 V -0080-2 Bussmann JJS-250 -0100-2 Bussmann JJS-300 -0120-2 Bussmann JJS-400 -0140-2 Bussmann JJS-500 -0170-2 Bussmann JJS-600 -0210-2 Bussmann...

  • Page 97: 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 98: Dimensions, Weights And Noise

    Dimensions, weights and noise Frame size UL type: open chassis Weight Noise Height Depth 44.13 13.15 16.36 18.31 61.57 16.35 22.14 22.36 height W1 width of the basic unit with PE terminal (bookshelf) W2 width with the cable connection terminal plates on the left side only (bookshelf) depth without fastening brackets (R7 bookshelf: depth with fastening brackets is 20.32 in.) (R8 bookshelf: depth with fastening brackets is 22.48 mm)

  • Page 99: Input Power Connection

    Approximately 98% at nominal power level Cooling Method Internal fan, flow direction from front to top Free space around the unit Refer to ACS800-04/04M/U4 Cabinet Installation [68360323 (English)]. Cooling air flow IEC data. Degrees of protection IP 00 (UL type: open chassis)

  • Page 100: Prevention Of Unexpected Start: Agps-21 Board

    Prevention of Unexpected Start: AGPS-21 board Nominal input voltage 115 VAC or 230 VAC Input voltage range 95...132 VAC (X3 on), 185...265 VAC (X4 on, default) (selected by jumper) Nominal frequency 50/60 Hz Current 0.77 A at 115 V, 0.44 A at 230 V Max.

  • Page 101: Materials

    Provisions for compliance: The final assembler of the machine is responsible for installing - an emergency-stop device - a supply disconnecting device - the ACS800-04/04M/U4 into a cabinet. • EN 60529: 1991 (IEC 529) Degrees of protection provided by enclosures (IP code) •...

  • Page 102: 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 (Directive 73/23/EEC, as amended by 93/68/EEC and Directive 89/336/ EEC, as amended by 2004/108EC). Definitions EMC stands for Electromagnetic Compatibility.

  • Page 103: Second Environment (Drive Of Category C3)

    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 104: C-Tick" Marking

    “C-tick” marking “C-tick” marking is required in Australia and New Zealand. A “C-tick” mark is attached to each drive in order to verify compliance with the relevant standard (IEC 61800-3 (2004) – Adjustable speed electrical power drive systems – Part 3: EMC product standard including specific test methods), mandated by the Trans-Tasman Electromagnetic Compatibility Scheme.

  • Page 105: Second Environment (Drive Of Category C3)

    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 drive is installed according to the instructions given in the Hardware Manual. 4. The motor and control cables used are selected as specified in the Hardware Manual.

  • Page 106: Ul/Csa Markings

    If you have any questions concerning your ABB drive, please contact the local distributor or ABB office. The technical data, information and specifications are valid at the time of printing. The manufacturer reserves the right to modifications without prior notice.

  • Page 107: Resistor Braking

    To which products this chapter applies This chapter applies to the ACS800-01/U1 (frame sizes R2 to R6), ACS800-02/U2 (frame sizes R7 and R8), ACS800-04/U4 (frame sizes R7 and R8) and ACS800-07/ U7 (frame sizes R6, R7 and R8). 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 108: 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 109 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 110 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 111: Acs800-07/U7

    Optional brake chopper and resistor(s) for the ACS800-02/U2, ACS800-04/ 04M/U4 and ACS800-07/U7 The nominal ratings for dimensioning the brake resistors for the ACS800-02/U2, ACS800-04/04M/U4 and ACS800-07/U7 are given below at an ambient temperature of 40 °C (104 °F). ACS800 type...
  • Page 112 ACS800 type Frame Braking power of the chopper and Brake resistor(s) size the drive 5/60 s 10/60 s 30/60 s Type Rcont (ohm) (kJ) (kW) br10 br30 brcont (kW) (kW) (kW) (kW) 690 V units -0070-7 SAFUR90F575 8.00 1800 -0100-7 SAFUR80F500 6.00 2400...

  • Page 113: Resistor Installation And Wiring

    Combined braking cycles for R7: Examples max 5 s or 10 s or P br10 br30 brcont No braking max 30 s min. 30 s max 30 s min. 30 s min. 30 s • After P or P braking, the drive and the chopper will withstand P continuously.

  • Page 114: Acs800-07/U7

    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 115: Brake Circuit Commissioning

    RMIO:X22 or X2: X22 +24VD +24VD Thermal switch DGND1 (standard in ABB re- Θ sistors) DGND2 DIIL For other control programs, the thermal switch may be wired to a different digital input.
  • Page 116 Resistor braking...
  • Page 118 ABB Oy ABB Inc. ABB Beijing Drive Systems Co. Ltd. AC Drives Automation Technologies No. 1, Block D, A-10 Jiuxianqiao Beilu P.O. Box 184 Drives & Motors Chaoyang District FI-00381 HELSINKI 16250 West Glendale Drive Beijing, P.R. China, 100015 FINLAND...

This manual is also suitable for:

Acs800-04mAcs800-u4

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