ABB ACQ810-04 Hardware Manual
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ABB ACQ810-04 Hardware Manual

Drive modules (200 to 500 kw, 300 to 700 hp)
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ACQ810-04 drive modules (200 to 500 kW, 300 to 700 hp)

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Summary of Contents for ABB ACQ810-04

  • Page 1 ABB industry-specific drives Hardware manual ACQ810-04 drive modules (200 to 500 kW, 300 to 700 hp)
  • Page 2 List of related manuals Drive hardware manuals and guides Code (English) ACQ810-04 drive modules (200 to 500 kW, 300 to 700 hp) hardware manual 3AUA0000120538 Safe torque off function for ACSM1, ACS850 and ACQ810 drives application 3AFE68929814 guide Drive firmware manuals and guides...
  • Page 3 Hardware manual ACQ810-04 drive modules (200 to 500 kW, 300 to 700 hp) Table of contents 1. Safety instructions 6. Installation 8. Start-up  2012 ABB Oy. All Rights Reserved. 3AUA0000120538 Rev A EFFECTIVE: 2012-06-27...

  • Page 5: Table Of Contents

    Table of contents 1. Safety instructions What this chapter contains ..........11 Use of warnings .
  • Page 6 HXR and AMA motors ..........48 ABB motors of types other than M2_, M3_, M4_, HX_ and AM_ ... . . 48 Calculating the rise time and the peak line-to-line voltage .
  • Page 7 Implementing a bypass connection ......... 60 Example bypass connection .
  • Page 8 Safe torque off (XSTO) ..........98 Control cable connection procedure of units with internal control unit (option +P905) .
  • Page 9 Providing feedback on ABB Drives manuals ....... . . 143...

  • Page 11: Safety Instructions

    Safety instructions 11 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 12: Safety In Installation And Maintenance

    12 Safety instructions Safety in installation and maintenance Electrical safety  These warnings are intended for all who work on the drive, motor cable or motor. WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment: •...

  • Page 13: Grounding

    Safety instructions 13 Grounding These instructions are intended for all who are responsible for the grounding of the drive. WARNING! Ignoring the following instructions can cause physical injury, death, increased electromagnetic interference and equipment malfunction: • Ground the drive, motor and adjoining equipment to ensure personnel safety in all circumstances, and to reduce electromagnetic emission and interference.

  • Page 14: General Safety

    14 Safety instructions General safety These instructions are intended for all who install and service the drive. WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment: • - Lift the drive module using the lifting lugs attached to the top and base of the unit. - Handle the drive module carefully.
  • Page 15 Safety instructions 15 • - Push the drive module into the cabinet and pull it from the cabinet carefully preferably with help from another person as shown below. Keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back.

  • Page 16: Fiber Optic Cables

    16 Safety instructions Fiber optic cables  WARNING! Ignoring the following instructions can cause equipment malfunction and damage to the fiber optic cables: • Handle the fiber optic cables with care. When unplugging optic cables, always grab the connector, not the cable itself. Do not touch the ends of the fibers with bare hands as the fiber is extremely sensitive to dirt.

  • Page 17: Introduction To The Manual

    Introduction to the manual 17 Introduction to the manual What this chapter contains This chapter describes the intended audience and contents of the manual. It contains a flowchart of steps in checking the delivery, installing and commissioning the drive. The flowchart refers to chapters/sections in this manual and other manuals.

  • Page 18: Categorization By Frame Size And Option Code

    18 Introduction to the manual Operation principle and hardware description describes the drive module. Planning the cabinet installation guides in planning drive cabinets and installing the drive module into a user-defined cabinet. The chapter gives cabinet layout examples and free space requirements around the module for cooling.
  • Page 19 Introduction to the manual 19 Task Unpack and check the units. Moving and unpacking the unit (page 67) Check that all necessary optional modules and equipment Checking the delivery (page 70) are present and correct. If the drive module has been non-operational Only intact units may be started up.
  • Page 20 20 Introduction to the manual Task Connect the external control cables to the drive control unit. Connecting the control cables (page 86) Control cable connection procedure of units with internal control unit (option +P905), page Check the installation. Installation checklist (page 101) Commission the drive.

  • Page 21: Terms And Abbreviations

    Introduction to the manual 21 Terms and abbreviations Term/Abbreviation Explanation AIBP Input bridge protection board APOW Power supply board BFPS Power supply board Direct torque control Electromagnetic compatibility Electromagnetic interference FDNA-01 Optional DeviceNet™ fieldbus adapter module FENA-11 Optional Ethernet/IP™ adapter module FIO-11 Optional analog I/O extension module FIO-21...
  • Page 22 22 Introduction to the manual...

  • Page 23: Operation Principle And Hardware Description

    This chapter describes the operating principle and construction of the drive module. Product overview The ACQ810-04 is a drive module for controlling asynchronous AC induction motors for water and wastewater industry pump applications. The main circuit of the drive module is shown below.

  • Page 24: Layout

    24 Operation principle and hardware description Layout The components of the standard unit are shown below. Control unit (JCU) Control panel Control cable clamp plate Item Description Lifting lugs Fastening bracket Circuit board compartment Power supply and fiber optic cables to be connected to the external control unit PE terminal Control cable duct Main cooling fans...
  • Page 25 Operation principle and hardware description 25 The drive module and optional selections are shown below. Item Description Drive module Input power cabling panel fastened to the drive module Output power cabling panel fastened to the drive module Front cover. With option +P905, the control panel is placed on this cover. Input power cabling panel (+H381) Side guides Output power cabling panel (+H381).

  • Page 26: Control Unit Variants

    26 Operation principle and hardware description Control unit variants Control unit without control panel Control unit without front Control unit with control and panel holder (+0J400) cover (+0C168 and +0J400) panel (standard) a) When covers are removed The control unit layout is shown below (cover assembly and protective coverings of the slots removed).

  • Page 27: Power Connections And Control Interfaces

    Operation principle and hardware description 27 Power connections and control interfaces  The diagram shows the power connections and control interfaces of the drive module. Control unit (JCU) Slot 1 Control panel or PC Slot 2 Slot 1 FIO-11 (Analog I/O extension) FIO-21 (Analog and digital I/O extension)

  • Page 28: External Control Unit Connection Cables

    The cables for connecting the drive module and control panel to the control unit are shown below. See sections Connecting the external control unit to the drive module (page 88) and Connecting a PC (page 99) for the actual connections. ACQ810-04 JRIB APOW 2560 mm (8.4 ft) JINT JGDR 3 m (9.8 ft)

  • Page 29: Type Designation Label

    The first digits from left express the basic configuration. The optional selections are given thereafter, separated by plus signs, eg, +J410. The main selections are described below. Not all selections are available for all types. For more information, refer to ACQ810-04 Ordering Information (3AXD00000588241), available on request. Code Description...
  • Page 30 30 Operation principle and hardware description Code Description Option codes (plus codes) Cabling panels H381 Power cabling panels (U1, V1, W1, U2, V2, W2 terminals) Pedestal 0H354 No pedestal Control panel and control unit 0J400 No control panel or panel holder J410 Control panel with door mounting kit.

  • Page 31: Planning The Cabinet 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.

  • Page 32: Planning The Layout Of The Cabinet

    32 Planning the cabinet installation Planning the layout of the cabinet Design a spacious layout to ensure easy installation and maintenance. Sufficient cooling air flow, obligatory clearances, cables and cable support structures all require space. Place the control board(s) away from: •...

  • Page 33: Layout Examples, Door Open

    Planning the cabinet installation 33 Layout examples, door open  Layout examples for units in IP22 and IP54 cabinets are shown below. Optional cabling panels (+H381) are not used. IP22 IP54 Air flow through the drive module (side view) Supporting frame of the cabinet IP54 Air baffles that separate the cool and hot areas (leak- proof lead-throughs)

  • Page 34: Arranging The Grounding Inside The Cabinet

    Always fasten the drive module from its fastening points to the cabinet. For details, see the module installation instructions. WARNING! Do not fasten the cabinet by electric welding. ABB does not assume any liability for damages caused by electric welding as the welding circuit may...

  • Page 35: Planning The Cabinet Placement On A Cable Channel

    Planning the cabinet installation 35 Planning the cabinet placement on a cable channel Note the following when planning to place the cabinet on a cable channel: • The cabinet structure must be sturdy enough. If the whole cabinet base will not be supported from below, the cabinet weight will lie on the sections that the floor carries.
  • Page 36 36 Planning the cabinet installation grounding is made with short flat copper braids for low inductance. One-point high- frequency grounding cannot be used due to the long distances inside the cabinet. • 360° high frequency grounding of the cable shields at the cable lead-throughs improves the EMC shielding of the cabinet.

  • Page 37: Planning The Grounding Of The Cable Shields At The Cabinet Lead-Through

    Planning the cabinet installation 37 Planning the grounding of the cable shields at the cabinet lead-through Follow the principle shown below when planning the grounding of the cable shields at the cabinet lead-through. To power cable terminals Cable shield PE (ground) terminal of the cabinet, cabling panel or drive module Stripped part of the cable EMC sleeve...

  • Page 38: Planning The Cooling

    38 Planning the cabinet installation Planning the cooling Note following guidelines when planning the cooling of the cabinet: • Ventilate the installation site sufficiently so that the cooling air flow and ambient temperature requirements of the drive module are met, see pages and 124.

  • Page 39: Preventing The Recirculation Of Hot Air

    Planning the cabinet installation 39 Preventing the recirculation of hot air Prevent hot air circulation outside the cabinet by leading the outcoming hot air away from the area where the inlet air to the cabinet is taken. Possible solutions are listed below: •...

  • Page 40: Required Free Space

    The module is designed to be installed in a cabinet with the following measurements: width 400 mm (15.75 in.), depth 600 mm (23.62 in.) and height 2000 mm (78.74 in.). Other installation positions Contact your local ABB representative.

  • Page 41: Planning The Placement Of The Control Panel

    Planning the cabinet installation 41 Planning the placement of the control panel Note the following alternatives when planning the placement of the control panel: • The control panel can be snapped on the control unit of the drive. See page 26. •...
  • Page 42 42 Planning the cabinet installation...

  • Page 43: 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 44: Other Regions

    44 Planning the electrical installation Other regions  The disconnecting device must conform to the applicable safety regulations. Selecting and dimensioning the main contactor If a main contactor is used, its utilization category (number of operations under load) must be AC-1 according to IEC 60947-4, Low-voltage switchgear and controlgear. Dimension the main contactor according to the nominal voltage and current of the drive.

  • Page 45: Requirements Table

    The following table shows how to select the motor insulation system and when optional ABB du/dt filters, insulated N-end (non-drive end) motor bearings and ABB common mode filters are required. Failure of the motor to fulfil the following requirements or improper installation may shorten motor life or damage the motor bearings and voids the warranty.
  • Page 46 46 Planning the electrical installation Motor type Nominal AC line Requirement for voltage Motor ABB du/dt and insulation common mode filters system and insulated N-end bearings 100 kW < P < 350 kW > 350 kW or frame size > IEC 400 IEC 315 <...

  • Page 47: Additional Requirements For High-Output Motors And Ip23 Motors

    EN 50347 (2001), or if the degree of protection is IP23, follow these guidelines when defining the protection of the motor: • The table below shows the requirements for ABB random-wound motor series (for example, M3AA, M3AP and M3BP). Nominal AC line...

  • Page 48: Hxr And Ama Motors

    All HXR machines manufactured in Helsinki starting 1.1.1998 have form-wound windings. ABB motors of types other than M2_, M3_, M4_, HX_ and AM_ Use the selection criteria given for non-ABB motors. 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.

  • Page 49: Selecting The Power Cables

    Planning the electrical installation 49 Selecting the power cables General rules  Dimension the input power and motor cables according to local regulations: • Dimension the cable to carry the drive load current. See chapter Technical data for the rated currents. •...

  • Page 50: Typical Power Cable Sizes

    The table below gives copper and aluminium cable types with concentric copper shield for the drives with nominal current. See also Terminal and lead-through data for the power cables on page 121. ACQ810-04 Cu cable type Al cable type Cu cable type Al cable type AWG/kcmil AWG/kcmil -377A-4 2 ×...

  • Page 51: Alternative Power Cable Types

    Planning the electrical installation 51 Alternative power cable types  The power cable types that can be used with the drive are represented below. Recommended: Symmetrical shielded cable: three phase conductors and a concentric or otherwise symmetrically constructed PE conductor, and a shield PE conductor Shield and shield...

  • Page 52: Additional Us Requirements

    52 Planning the electrical installation Additional US requirements  Use type MC continuous corrugated aluminum armor cable with symmetrical grounds or shielded power cable for the motor cables if metallic conduit is not used. For the North American market, 600 V AC cable is accepted for up to 500 V AC. For drives rated over °...

  • Page 53: Signals Allowed To Be Run In The Same Cable

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

  • Page 54: Separate Control Cable Ducts

    54 Planning the electrical installation Separate control cable ducts  230 V 230 V (120 V) (120 V) 24 V 24 V Lead 24 V and 230 V (120 V) control Not allowed unless the 24 V cable is cables in separate ducts inside the insulated for 230 V (120 V) or insulated cabinet.

  • Page 55: Implementing Thermal Overload And Short-Circuit Protection

     Protect the drive with fuses (1) and the input cable with fuses (2) or a circuit breaker (3) as shown below: ACQ810-04 ACQ810-04 Size the fuses or circuit breaker at the distribution board according to local regulations for the input cable protection. Select the fuses for the drive according to the instructions given...

  • Page 56: Protecting The Motor Against Thermal Overload

    56 Planning the electrical installation Protecting the motor against thermal overload  According to regulations, the motor must be protected against thermal overload and the current must be switched off when overload is detected. The drive includes a motor thermal protection function that protects the motor and switches off the current when necessary.

  • Page 57: Implementing The Safe Torque Off (Sto) Function

    Start up and validate the Safe torque off function according to Safe torque off function for ACS850 and ACQ810 application guide (3AFE68929814 [English]). The manual includes the safety data for the function. Safe torque off ACQ810-04 Activation switch connection on JCU XSTO:1...

  • Page 58: Implementing The Power Loss Ride-Through Function

    58 Planning the electrical installation Implementing the Power loss ride-through function Implement the power loss ride-through function as follows: 1. Activate the power loss ride-through function of the drive (parameter 47.02 Undervolt ctrl in the Standard Pump Control Program). 2. If the installation is equipped with a main contactor, prevent its tripping at the input power break.

  • Page 59: Using A Contactor Between The Drive And The Motor

    Planning the electrical installation 59 Using a contactor between the drive and the motor Arrange the control of the output contactor by applying one of the alternatives described below. Alternative 1: When you have selected to use the default motor control mode (DTC) and motor coast stop in the drive, open the contactor as follows: 1.

  • Page 60: Implementing A Bypass Connection

    60 Planning the electrical installation Implementing a bypass connection If bypassing is required, employ mechanically or electrically interlocked contactors between the motor and the drive and between the motor and the power line. Ensure with interlocking that the contactors cannot be closed simultaneously. WARNING! Never connect the supply power to the drive output terminals U2, V2 and W2.

  • Page 61: Switching The Motor Power Supply From Drive To Direct-On-Line

    Planning the electrical installation 61 Switching the motor power supply from drive to direct-on-line 1. Stop the drive and the motor with the drive control panel (drive in the local control mode) or the external stop signal (drive in the remote control mode). 2.

  • Page 62: Connecting A Motor Temperature Sensor To The Drive I/O

    62 Planning the electrical installation Connecting a motor temperature sensor to the drive I/O WARNING! IEC 60664 requires double or reinforced insulation between live parts and the surface of accessible parts of electrical equipment which are either 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: 1.

  • Page 63: Installation

    Installation 63 Installation What this chapter contains In this chapter, the drive module is installed in a 400 mm wide Rittal TS 8 cabinet in a bookshelf way of mounting: The module is placed in an upright position on the cabinet bottom with its front facing the cabinet door.
  • Page 64 See Bottom plate on page 138. Always follow the general rules given in this chapter and local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches local laws and/or other regulations.
  • Page 65 Installation 65 Note 4: Mounting the drive module to an assembly panel Mount the assembly support as shown below. M4×12 Torx...
  • Page 66 66 Installation Note 5: Mounting the rubber grommet of units with optional cabling panels (+H381) Installing the input power cables through the rubber grommet of optional cabling panels provides the degree of protection of IP20 for the unit. Mount the grommet (if used) as follows: 1.

  • Page 67: Safety

    Installation 67 Safety WARNING! Only qualified electricians are allowed to carry out the electrical installation work described in this chapter. Follow the Safety instructions on the first pages of this manual. Ignoring the safety instructions can cause injury or death. Checking the installation site The material below the drive must be non-flammable and strong enough to carry the weight of the drive.
  • Page 68 68 Installation Description of the package contents Input cabling panel (option +H381), see contents below. Output cabling panel (option +H381), see contents below. Plywood support Drive module with factory installed options and multilingual residual voltage warning sticker, top guide plate, pedestal guide plate, telescopic ramp package, fastening screws in a plastic bag, external control unit with control cable clamp plate and factory installed optional modules, control panel with door mounting kit (option +J410), delivery documents, printed Hardware manual and multilingual Quick start-up guide and manuals CD.
  • Page 69 Installation 69 Ramp package contents Screw package Fastening bracket Telescopic extraction and insertion ramp PE terminal Cardboard box Pedestal guide plate Top guide plate Support Output power cabling panel (option +H381) package contents Paper fill Cardboard tray Top cardboard cover Support Bands Plastic bag...

  • Page 70: Checking The Delivery

    70 Installation Input power cabling panel (option +H381) package contents Screw package Paper fill Input power cabling panel Cardboard tray Top cardboard cover Support Bands Plastic bag Rubber grommet Grounding busbar to be connected to the input power cabling panel and the drive module *) *) If you cannot find the busbar in this package, it can be found in the output...

  • Page 71: Motor And Motor Cable

    Earth conductor using a measuring voltage of 500 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 72: Overall Flowchart Of The Installation Process

    72 Installation Overall flowchart of the installation process This flowchart describes the installation process of the units listed under What this chapter contains on page 63. Step Task For instructions, see Install the Rittal parts, cabinet bottom plate, drive Installing the mechanical accessories into the bottom guide plate and top guide and loose drive cabinet, page...
  • Page 73 Installation 73 Note: If the thickness of the bottom plate is not 2.5 mm (0.1 in.), adjust the dimensions accordingly. 4. Install the output cabling panel. 5. Install the side guides to the output cabling panel (2 screws for each side guide). 6.
  • Page 74 74 Installation 7. Mount the side guides to the input cabling panel (2 screws for each side guide) and mount the input cabling panel to the punched section.

  • Page 75: Assembly Drawing (Frame G1)

    Installation 75 Assembly drawing (frame G1)

  • Page 76: Assembly Drawing (Frame G2)

    76 Installation Assembly drawing (frame G2)

  • Page 77: Connecting The Power Cables

    Connecting the power cables WARNING! Follow the safety instructions, page 11. Ignoring the instructions can cause physical injury or death, or damage to the equipment Connection diagram  (PE) (PE) ACQ810-04- V1 W1 UDC+ ...+H381 V1 W1 UDC+ INPUT OUTPUT...

  • Page 78: Power Cable Connection Procedure

    78 Installation For alternatives, see section Selecting the supply disconnecting device on page In the mounting example of this chapter, the disconnecting device is not in the same cubicle with the drive module. If a shielded cable is used (not required but recommended) and the conductivity of the shield is <...
  • Page 79 Installation 79 Note: The input and output power cables must fit inside the area marked with diagonal lines in the image below to avoid chafing of the cables when the drive module is inserted into the cabinet. U1, V1, W1 102 mm (4 in.) U2, V2, W2 View without cabinet side plate in place.

  • Page 80: Mounting The Drive Module Into The Cabinet

    80 Installation Ground the motor cable shield at the motor end as follows: • 360 degrees at the lead-through of the motor terminal box (1) • or by twisting the shield as follows: flattened width > 1/5 · length. b > 1/5 · a Mounting the drive module into the cabinet WARNING! Follow the safety instructions, page 11.

  • Page 81: Mounting Procedure

    Installation 81 Mounting procedure  1. Mount the fastening bracket to the drive module. M8×12 Hex 2. Mount the grounding busbar that has been previously mounted to the input cabling panel to the drive module. M8×12 Hex 3. Install the extraction and insertion ramp to the cabinet base with two screws. 4.
  • Page 82 82 Installation 6. Connect the busbars of the drive module to the busbars of the cabling panels. combi screw M12, 70 N·m (52 lbf·ft). 7. Mount the drive module to the cabinet from top and bottom as shown below and in the assembly drawing on page (frame G1) or page (frame...
  • Page 83 Installation 83...

  • Page 84: Assembly Drawing Of Installing The Drive Module To The Cabinet (Frame G1)

    84 Installation Assembly drawing of installing the drive module to the cabinet (frame G1)

  • Page 85: Assembly Drawing Of Installing The Drive Module To The Cabinet (Frame G2)

    Installation 85 Assembly drawing of installing the drive module to the cabinet (frame G2)

  • Page 86: Removing The Protective Covering From The Module Air Outlet

    86 Installation Removing the protective covering from the module air outlet WARNING! Remove the protective covering from the top of the drive module after the installation. If the covering is not removed, the cooling air cannot flow freely through the module and the drive will run to overtemperature. Connecting the control cables Flowchart of the control cable installation process (external control ...

  • Page 87: Removing The Cover Assembly Of The External Control Unit

    Installation 87 Removing the cover assembly of the external control unit  The cover assembly needs to be removed before the installation of optional modules and the connection of control cabling. Follow this procedure to remove the cover assembly. The numbers refer to the illustrations below. 1.

  • Page 88: Fastening The Control Cable Clamp Plate

    88 Installation Fastening the control cable clamp plate  Fasten the control cable clamp plate either to the top or base of the control unit with four screws as shown below. 0.7 N·m (6.2 lbf·in) Connecting the external control unit to the drive module ...
  • Page 89 Installation 89 JRIB JRIB APOW RXD = receiver TXD = transmitter 3AUA0000038989...

  • Page 90: Mounting The External Control Unit

    90 Installation Mounting the external control unit  The drive control unit can be fastened on a mounting plate through the fastening holes in its back or by using a DIN rail. Mounting the external control unit to wall 1. Fasten the fastening screws in the wall. 2.

  • Page 91: Mounting The Control Unit Horizontally On A Din Rail

    Installation 91 Mounting the control unit horizontally on a DIN rail 1. Fasten the latches (A) to the back of the control unit with three screws. 2. Click the control unit to the rail as shown below (B). 3aua0000038989 Installing optional modules Mechanical installation Optional modules such as a fieldbus adapters, an I/O extensions and the pulse encoder interfaces are inserted in the optional module slot on the control unit.

  • Page 92: Wiring The Modules

    92 Installation Note: Correct installation of the screw is essential for fulfilling the EMC requirements and for proper operation of the module. Wiring the modules See the appropriate optional module manual for specific installation and wiring instructions. See page for routing the cables.

  • Page 93: Connecting The Control Cables To The Terminals Of The Control Unit

    Installation 93 Connecting the control cables to the terminals of the control unit  1. Route the cables to the control unit as shown below. 3. Use shrink tubing or tape to contain strands 2. Run cables through the cover mounting bracket Remove outer jacket of cable at clamp to expose cable shield.
  • Page 94 94 Installation same ground line with no significant voltage drop between the end points.Tighten the screws to secure the connection. 3. Connect the conductors to the appropriate detachable terminals of the control unit. See section Jumpers, page Use shrink tubing or insulating tape to contain any stray strands.

  • Page 95: Default I/O Connection Diagram

    Installation 95 Default I/O connection diagram  XPOW Notes: External power input +24VI […] denotes default setting with ACQ810 24 V DC, 1.6 A standard pump control program (Factory XRO1, XRO2 defs macro). See Firmware manual for Relay output RO1 [Ready] other macros.

  • Page 96: Jumpers

    96 Installation Jumpers DI/DIO grounding selector (located between XD24 and XDI) – Determines whether the DIGND (ground for digital inputs DI1…DI4) floats, or if it is connected to DIOGND (ground for DI5, DIO1 and DIO2). See the JCU isolation and grounding diagram on page 124. If DIGND floats, the common of digital inputs DI1…DI4 should be connected to XD24:2.

  • Page 97: External Power Supply For The Jcu Control Unit (Xpow)

    Installation 97 External power supply for the JCU control unit (XPOW) External +24 V (minimum 1.6 A) power supply for the control unit can be connected to terminal block XPOW. Using an external supply is recommended if • the application requires fast start after connecting the drive to the main supply •...

  • Page 98: Start Interlock (Xdi:a)

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

  • Page 99: Control Cable Connection Procedure Of Units With Internal Control Unit (Option +P905)

    Note: Keep any signal wire pairs twisted as close to the terminals as possible. Twisting the wire with its return wire reduces disturbances caused by inductive coupling. Connecting a PC Connect the PC to the drive control unit as follows:. ACQ810-04...
  • Page 100 100 Installation...

  • Page 101: Installation Checklist

    Installation checklist 101 Installation checklist What this chapter contains This chapter contains a list for checking the mechanical and electrical installation of the drive. Installation checklist Go through the checklist below together with another person. WARNING! Follow the safety instructions, page 11. Ignoring the instructions can cause physical injury or death, or damage to the equipment Check that …...
  • Page 102 102 Installation checklist Check that … Drive option modules and other components Type and number of option modules and other equipment is correct. Option modules and other equipment are not damaged. Option modules and terminals are labelled correctly. The placement of option modules and other equipment inside the cabinet and on the cabinet door is correct.
  • Page 103 Installation checklist 103 Check that … The cooling air will flow freely in and out of the drive cabinet, and air recirculation inside the cabinet will not be possible (air baffle plates are on place). If the drive has been stored over one year: The electrolytic DC capacitors in the DC link of the drive have been reformed.
  • Page 104 104 Installation checklist...

  • Page 105: Start-Up

    Start-up 105 Start-up What this chapter contains This chapter refers to the start-up instructions of the cabinet-installed drive. Start-up 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 106 106 Start-up...

  • Page 107: Fault Tracing

    Fault tracing 107 Fault tracing What this chapter contains This chapter describes the fault tracing possibilities of the drive. LEDs This table describes LEDs of the drive module. Where When the LED is lit JINT board V204 (green) +5 V voltage of the board is OK. V309 (red) Not in use.
  • Page 108 108 Fault tracing...

  • Page 109: Maintenance

    The drive module replacement described in this chapter applies to the Rittal TS 8 example installation of chapter Installation. The other maintenance instructions are general. 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...

  • Page 110: Cabinet

    The battery is housed on the rear of replacement. the control panel. Replace with a new CR 2032 battery. Consult your local ABB Service representative for more details on the maintenance. On the Internet, go to http://www.abb.com/drivesservices. Cabinet Cleaning the interior of the cabinet ...

  • Page 111: Heatsink

    Maintenance 111 Heatsink The module heatsink fins pick up dust from the cooling air. The drive runs into overtemperature warnings and faults if the heatsink is not clean. Cleaning the interior of the heatsink  WARNING! Follow the safety instructions, page 11. Ignoring the instructions can cause physical injury or death, or damage to the equipment.

  • Page 112: Fans

    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. Replacing the circuit board compartment cooling fan ...

  • Page 113: Replacing The Main Cooling Fans

    Maintenance 113 Replacing the main cooling fans  WARNING! Follow the safety instructions, page 11. Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Remove the drive module out of the cabinet as described in section Replacing the drive module on page 114.

  • Page 114: Replacing The Drive Module

    114 Maintenance Replacing the drive module WARNING! Follow the safety instructions, page 11. Ignoring the instructions can cause physical injury or death, or damage to the equipment. Handle the drive module carefully. Make sure that the module does not fall down when moving it on the floor and during installation and maintenance work: Open the support legs by pressing each leg a little down and turning it aside (1, 2).
  • Page 115 Maintenance 115 8. Pull the drive module carefully out of the cabinet preferably with help from another person. 9. Install the new module in reverse order to the above.

  • Page 116: Capacitors

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

  • Page 117: Technical Data

    The ratings of the drive modules with 400 and 480 V AC (50 Hz and 60 Hz) supply are given below. Drive type Frame Input Output ratings size ratings Nominal IEC M2/M3 UL NEMA ACQ810-04... P (kW) P (hp) cont =400 V =480 V -377A-4 -480A-4 -570A-4 -634A-4 -700A-4...

  • Page 118: Derating

    Note 2: To achieve the rated motor power given in the table, the rated current of the drive must be higher than or equal to the rated motor current. The DriveSize dimensioning tool available from ABB is recommended for selecting the drive, motor and gear combination.

  • Page 119: Fuses (Iec)

    Note 4: Fuses from other manufacturers can be used if they meet the ratings and the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table. Note 5: For UL fuses, contact ABB. 00581898...

  • Page 120: Dimensions, Weights And Free Space Requirements

    120 Technical data Dimensions, weights and free space requirements Drive type Weight 1 ACQ810-04 -377A-4 1462 1560 -480A-4 1462 1560 -570A-4 1462 1560 -634A-4 1462 1560 -700A-4 1662 1710 -785A-4 1662 1710 -857A-4 1662 1710 Drive type Weight 1 ACQ810-04 -377A-4 57.56...

  • Page 121: Losses, Cooling Data And Noise

    In units without optional cabling panels (option +H381 not selected), it is possible to use the maximum cable size (4 × (3 × 240) mm2 or 4 × (3 × 500 AWG) only with special cable lugs and additional insulation. For more information, contact your local ABB representative.

  • Page 122: Electrical Power Network Specification

    122 Technical data Electrical power network specification Voltage (U 380...500 VAC 3-phase ± 10% Rated conditional short- 65 kA when protected by fuses given in the fuse tables circuit current (IEC 60439-1) Frequency 48 to 63 Hz, maximum rate of change 17%/s Imbalance Max.
  • Page 123 Technical data 123 Digital inputs/outputs DIO1 Connector pitch 3.5 mm, wire size 1.5 mm and DIO2 As inputs: (XDIO:1 and XDIO:2) 24 V logic levels: “0” < 5 V, “1” > 15 V Input/output mode selection by : 2.0 kohm parameters.

  • Page 124: Efficiency

    124 Technical data Isolation and grounding diagram 9,1 5212 52&20 521& 5212 52&20 521& 9' *1'B', 9' *1'B',2 ',,/ ',2 ',2 95() 95() $*1' $, &RPPRQ PRGH YROWDJH $, $, EHWZHHQ FKDQQHOV “  9 $, $2 $2 $2 $2 %*1' 287 287...

  • Page 125: Materials

    EU. They must be removed and handled according to local regulations. For further information on environmental aspects and more detailed recycling instructions, please contact your local ABB distributor. Applicable standards The drive complies with the following standards. The compliance with the European Low Voltage Directive is verified according to standards EN 61800-5-1 and EN 60204-1.

  • Page 126: Ce Marking

    126 Technical data EN 61800-3:2004 Adjustable speed electrical power drive systems. Part 3: EMC requirements and specific test methods EN 61800-5-2:2007 Adjustable speed electrical power drive systems. Part 5-2: Safety requirements – Functional UL 508C (2002) UL Standard for Safety, Power Conversion Equipment, second edition CSA C22.2 No.

  • Page 127: 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 128 128 Technical data...

  • Page 129: Dimension Drawings

    Dimension drawings 129 Dimension drawings What this chapter contains This chapter contains dimension drawings of the drive modules with optional parts for Rittal TS 8 cabinet assembly.

  • Page 130: Frame G1 - Drive Module Dimensions

    130 Dimension drawings Frame G1 – Drive module dimensions...

  • Page 131: Frame G1 - Drive Module Dimensions With Optional Cabling Panels (+H381)

    Dimension drawings 131 Frame G1 – Drive module dimensions with optional cabling panels (+H381)
  • Page 132 132 Dimension drawings...

  • Page 133: Frame G1 - Cabling Panels (+H381) Installed Into A Rittal Ts 8 Cabinet

    Dimension drawings 133 Frame G1 – Cabling panels (+H381) installed into a Rittal TS 8 cabinet...

  • Page 134: Frame G2 - Drive Module Dimensions

    134 Dimension drawings Frame G2 – Drive module dimensions...

  • Page 135: Frame G2 - Drive Module Dimensions With Optional Cabling Panels (+H381)

    Dimension drawings 135 Frame G2 – Drive module dimensions with optional cabling panels (+H381)
  • Page 136 136 Dimension drawings...

  • Page 137: Frame G2 - Cabling Panels (+H381) Installed Into A Rittal Ts 8 Cabinet

    Dimension drawings 137 Frame G2 – Cabling panels (+H381) installed into a Rittal TS 8 cabinet...

  • Page 138: Bottom Plate

    138 Dimension drawings Bottom plate...

  • Page 139: Example Circuit Diagrams

    Example circuit diagrams 139 Example circuit diagrams What this chapter contains This chapter shows an example circuit diagram for a cabinet-installed drive module.

  • Page 140: Example Circuit Diagram

    140 Example circuit diagrams Example circuit diagram This diagram is an example for the main wiring of a drive cabinet. Note that the diagram includes components which are not included in a basic delivery (* plus code options, ** other options, *** to be acquired by the customer).

  • Page 141: Du/Dt Filters

    ACQ810-04... -377A-4 FOCH0610-70 -480A-4 FOCH0610-70 -570A-4 FOCH0610-70 -634A-4 FOCH0610-70 -700A-4 FOCH0610-70 -785A-4 -857A-4 00581898 * Contact ABB for the filter type. Description, installation and technical data of the FOCH filters  See FOCH du/dt filters hardware manual (3AFE68577519 [English]).
  • Page 142 142 du/dt filters...

  • Page 143: 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/drives...
  • Page 144 Contact us www.abb.com/drives www.abb.com/drivespartners...

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