ABB ACS850-04 Hardware Manual
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ABB ACS850-04 Hardware Manual

Drive modules 0.37 to 45 kw, 0.5 to 60 hp
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ACS850-04 drive modules (0.37 to 45 kW, 0.5 to 60 hp)

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Summary of Contents for ABB ACS850-04

  • Page 1 ABB machinery drives Hardware manual ACS850-04 drive modules (0.37 to 45 kW, 0.5 to 60 hp)

  • Page 2: List Of Related Manuals

    ACS850-04 drive modules (0.37 to 45 kW, 0.5 to 60 hp) hardware manual 3AUA0000045496 ACS850-04 drive modules (0.37 to 45 kW, 0.5 to 60 hp) quick installation guide 3AUA0000045495 Safe torque off function for ACSM1, ACS850 and ACQ810 drives application...
  • Page 3 ACS850-04 drive modules 0.37 to 45 kW, 0.5 to 60 hp Hardware manual 3AUA0000045496 Rev F EFFECTIVE: 2013-02-28  2013 ABB Oy. All Rights Reserved.

  • Page 5: Safety Instructions

    Safety instructions What this chapter contains This chapter contains 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, the 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 • The drive is not field repairable. Never attempt to repair a malfunctioning drive; contact your local ABB representative or Authorized Service Center for replacement. • Make sure that dust from drilling does not enter the drive during the installation.

  • Page 8: Start-Up And Operation

    Start-up and operation These warnings are intended for all who plan the operation of the drive, start up 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 9: Table Of Contents

    Table of contents List of related manuals ............2 Safety instructions What this chapter contains .
  • Page 10 Cabinets with multiple modules ......... . .34 Cabinet heaters .
  • Page 11 Electrical installation What this chapter contains ............53 Removing the cover assembly .
  • Page 12 Other maintenance actions ............81 Transferring the memory unit to a new drive module .
  • Page 13 Brake choppers and resistors with the ACS850-04 ........
  • Page 14 Providing feedback on ABB Drives manuals ........

  • Page 15: Introduction To This Manual

    The flowchart refers to chapters/sections in this manual and other manuals. Compatibility The manual is compatible with the ACS850-04 drive modules of frame sizes A to D. Intended audience This manual is intended for people who plan the installation, install, commission, use and service the drive.
  • Page 16 Operation principle and hardware description describes the drive module. Planning the cabinet assembly guides in planning the installation of the drive module into a user-defined cabinet. Mechanical installation instructs how to place and mount the drive. Planning the electrical installation instructs on the motor and cable selection, the protections and the cable routing.

  • Page 17: Installation And Commissioning Flowchart

    If the converter has been non-operational for more than one year, the converter DC link Only intact units may be started up. capacitors need to be reformed. Ask ABB for more information. Check the installation site. Mechanical installation: Before installation...
  • Page 18 Task Connect the power cables. Electrical installation: Power cable connection (page 56) and Connecting the control cables Connect the control and the auxiliary control cables. (page 66) For optional equipment: Mains chokes (page 101) EMC filters (page 103) Resistor braking (page 113) Manuals for any optional equipment Check the installation.

  • Page 19: Terms And Abbreviations

    Terms and abbreviations Term/Abbreviation Explanation CHK-xx Series of optional mains chokes Embedded fieldbus Electromagnetic compatibility FIO-01 Optional digital I/O extension module FIO-11 Optional analog I/O extension module FIO-21 Optional analog/digital I/O extension module FEN-01 Optional TTL encoder interface module FEN-11 Optional absolute encoder interface module FEN-21 Optional resolver interface module...
  • Page 20 Introduction to this manual...

  • Page 21: Operation Principle And Hardware Description

    CHK-xx mains choke (see chapter Mains chokes on page 101) UDC+ UDC– V1 W1 JFI-xx EMC filter (see chapter EMC filters on page 103) ACS850-04 Rectifier – Capacitor bank Inverter Brake chopper (see chapter Resistor braking page 113) V2 W2 R–...

  • Page 22: Motor Control

    ABB synchronous reluctance motors. It is to be installed into a cabinet by the customer. The ACS850-04 is available in several frame sizes depending on output power. All frame sizes use the same control unit (type JCU).

  • Page 23: Layout

    Layout Drive module, frame size A JCU control unit with cover assembly removed DC connection AC supply connection Power unit External 24 V power input JCU control unit with optional cover assembly Relay outputs +24 V output Digital inputs Digital input/outputs Slots 1 and 2 for Analog inputs optional I/O extension...

  • Page 24: Power Connections And Control Interfaces

    Power connections and control interfaces The diagram shows the power connections and control interfaces of the drive. Control unit (JCU) Slot 1 / Slot 2 FIO-01 (Digital I/O extension) FIO-11 (Analog I/O extension) FIO-21 (Digital/Analog I/O Slot 1 extension) FEN-01 (Incremental [TTL] encoder interface) FEN-11 (Absolute encoder interface)

  • Page 25: Type Designation Label

    Type designation label The type designation label includes an IEC and NEMA rating, CE, C-UL US, and CSA markings, a type designation and a serial number, which allow individual recognition of each unit. The label is located on the left-hand side of the drive module.

  • Page 26: Type Designation Key

    The type designation key contains information on the specifications and configuration of the drive. The first digits from left express the basic configuration (e.g. ACS850-04-04A8-5). The optional selections are given thereafter, preceded by + signs (e.g. +L501). The main selections are described below. Not all selections are necessarily available for all types;...
  • Page 27 Selection Alternatives Printed hardware and R... +R700: English firmware manuals in +R701: German specified language +R702: Italian +R703: Dutch (The delivered manual set +R704: Danish can include manuals in +R705: Swedish English if the translation is +R706: Finnish not available.) +R707: French +R708: Spanish +R709: Portuguese...
  • Page 28 Operation principle and hardware description...

  • Page 29: Planning The Cabinet Assembly

    Please note that the installation must, however, 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 30: Main Dimensions And Free Space Requirements

    Main dimensions and free space requirements The modules can be installed side by side. The dimensions of the drive modules as well as free space requirements are presented below. For more details, refer to chapter Dimension drawings. Frame D Frame C Frame B Frame A Planning the cabinet assembly...

  • Page 31: Cooling And Degrees Of Protection

    Note: EMC filters of type JFI-x1 mounted directly above the drive module do not increase the free space requirements. (For EMC filters of type JFI-0x, see the dimension drawing of the filters on page 127.) 200 mm [7.9”] 300 mm [12”] The temperature of the cooling air entering the unit must not exceed the maximum allowed ambient temperature (see Ambient conditions...
  • Page 32 The drawing below shows two typical cabinet cooling solutions. The air inlet is at the bottom of the cabinet, while the outlet is at the top, either on the upper part of the door or on the roof. Air outlet Air inlet Arrange the cooling of the modules so that the requirements given in chapter Technical data...

  • Page 33: Preventing The Recirculation Of Hot Air

    Preventing the recirculation of hot air Cabinet (side view) AREA Main airflow out Air baffle plates COOL AREA Main airflow in Outside the cabinet 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 34: Cabinets With Multiple Modules

    Cabinets with multiple modules The hot air from a drive module must not enter another module. In a cabinet with multiple modules, a practical way is to install a wall to separate the cool area (at the front part of the cabinet) from the hot area (back part). The wall can be fastened to two vertical pillars on both left and right.

  • Page 35: Cabinet Heaters

    Cabinet heaters Use a cabinet heater if there is a risk of condensation in the cabinet. Although the primary function of the heater is to keep the air dry, it may also be required for heating at low temperatures. When placing the heater, follow the instructions provided by its manufacturer.
  • Page 36 Planning the cabinet assembly...

  • Page 37: Mechanical Installation

    Mechanical installation Contents of the package The drive is delivered in a cardboard box. To open, remove any banding and lift the top off the box. Mechanical installation...
  • Page 38 • printed Quick Guides, printed manuals if ordered, manuals CD. Compartments for EMC/RFI filter and control panel cable clamp plates mounting kit (Underneath the drive module – lift out the module and open left-hand side flap to access) Compartment for terminal blocks and manuals ACS850-04 drive module Mechanical installation...

  • Page 39: Delivery Check And Drive Module Identification

    Delivery check and drive module identification Check that there are no signs of damage. Before attempting installation and operation, check the information on the type designation label of the drive module to verify that the unit is of the correct type. See section Type designation label.

  • Page 40: Installation Procedure

    Installation procedure Direct surface mounting 1. Mark the locations for the four holes. The mounting points are shown in Dimension drawings. 2. Fix the screws or bolts to the marked locations. 3. Position the drive onto the screws on the surface. Note: Only lift the drive by its chassis.

  • Page 41: Mains Choke Installation

    Mains choke installation See chapter Mains chokes on page 101. EMC filter installation See chapter EMC filters on page 103. Brake resistor installation See chapter Resistor braking on page 113. Mechanical installation...
  • Page 42 Mechanical 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.

  • Page 44: Thermal Overload And Short Circuit Protection

    The protective characteristics of circuit breakers depend on the supply voltage as well as the type and construction of the breakers. There are also limitations pertaining to the short-circuit capacity of the supply network. Your local ABB representative can help you in selecting the breaker type when the supply network characteristics are known.

  • Page 45: Motor Thermal Protection

    Motor thermal protection According to regulations, the motor must be protected against thermal overload and the current must be switched off when overloading is detected. The drive includes a motor thermal protection function that protects the motor and switches off the current when necessary.

  • Page 46: Safe Torque Off Function

    Safe torque off function The drive supports the Safe torque off function. For more information, see Safe torque off function for ACSM1, ACS850 and ACQ810 application guide (3AFE68929814 [English]). Selecting the power cables General rules Dimension the supply (input power) and motor cables according to local regulations.

  • Page 47: Alternative Power Cable Types

    Alternative power cable types Power cable types that can be used with the drive are represented below. Motor cable (also recommended for supply cabling) Symmetrical shielded cable: three phase conductors and Note: A separate PE conductor is required if the a concentric or otherwise symmetrically constructed PE conductivity of the cable shield is not sufficient for the conductor, and a shield...

  • Page 48: 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 49: Considering The Pelv Requirements At Sites Above 2000 M (6562 Ft)

    Install the protective component as close to the inductive load as possible, not at the relay output. 230 V AC 230 V AC + 24 V DC Considering the PELV requirements at sites above 2000 m (6562 ft) The relay outputs of the drive do not fulfil the Protective Extra Low Voltage (PELV) requirements at installation sites above 4000 meters (13123 feet) if used with a voltage greater than 48 V.

  • Page 50: Selecting The Control Cables

    Control panel cable The cable connecting the control panel to the drive must not exceed 3 metres (9.8 ft) in length. The cable type tested and approved by ABB is used in control panel option kits. Connection of a motor temperature sensor to the drive I/O See page 68.

  • Page 51: Control Cable Ducts

    Where control cables must cross power cables make sure they are arranged at an angle as near to 90 degrees as possible. Do not run extra cables through the drive. The cable trays must have good electrical bonding to each other and to the grounding electrodes.
  • Page 52 Planning the electrical installation...

  • Page 53: 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 54 Electrical installation...

  • Page 55: Checking The Insulation Of The Assembly

    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 56: Power Cable Connection

    Mains chokes (page 101). JFI-xx EMC filter (optional). See chapter filters (page 103). The UDC+/UDC– connectors can be used for common DC configurations. See page 63. ACS850-04 UDC+ UDC– R– du/dt filter(s) (optional). See chapter du/dt and common mode filtering (page 109).

  • Page 57: Procedure

    Procedure Cabling drawings with tightening torques for each frame size are presented on pages to 62. 1. Frame sizes C and D only: Remove the two plastic connector covers at the top and bottom of the drive. Each cover is fastened with two screws. 2.

  • Page 58: Grounding The Motor Cable Shield At The Motor End

    11. With frame size C or D, cut suitable slots on the edges of the connector covers to accommodate the supply and motor cables. Install the covers again. (Tighten the screws to 3 N·m [25 lbf·in]). 12. Secure the cables outside the unit mechanically. 13.

  • Page 59: Installation Of Power Cable Clamp Plates

    Installation of power cable clamp plates Two identical power cable clamp plates are included with the drive. The picture below depicts a frame size A drive; the installation is similar with other frame sizes. Note: Pay attention to supporting the cables adequately within the installation enclosure especially if not using the cable clamps.

  • Page 60: Power Cable Connection - Frame Size A

    Power cable connection – frame size A Supply cable Cable clamp on bare shield 1.5 N·m (13 lbf·in) Below cable clamp, cover bare shield with insulating tape 1.5 N·m (13 lbf·in) 0.5 … 0.6 N·m (4.4 … 5.3 lbf·in) 0.5 … 0.6 N·m (4.4 … 5.3 lbf·in) 1.5 N·m (13 lbf·in) Above cable clamp, cover bare shield with insulating tape...

  • Page 61: Power Cable Connection - Frame Size B

    Power cable connection – frame size B Supply cable Cable clamp on bare shield 1.5 N·m (13 lbf·in) Below cable clamp, cover bare shield with insulating tape 1.5 N·m (13 lbf·in) 1.2 … 1.5 N·m (10.6 … 13.3 lbf·in) 1.5 N·m (13 lbf·in) Above cable clamp, cover bare shield with insulating tape Cable clamp on bare shield...

  • Page 62: Power Cable Connection - Frame Sizes C And D (Connector Covers Removed)

    Power cable connection – frame sizes C and D (connector covers removed) Supply cable Screw lug detail Below cable clamp, cover bare Cable clamp on bare shield shield with insulating tape 15 N·m (11 lbf·ft) 1.5 N·m (13 lbf·in) Frame C: 3 N·m (25 lbf·in) Frame D: 18 N·m (160 lbf·in)

  • Page 63: Dc Connection

    DC connection The UDC+ and UDC– terminals are intended for common DC configurations of a number of ACS850 drives, allowing regenerative energy from one drive to be utilised by the other drives in motoring mode. One or more drives are connected to the AC supply depending on the power requirement.
  • Page 64 UDC+ UDC- V1 W1 – Pre-charging circuit V2 W2 The ratings of the DC connection are given on page 91. For more information on common DC configurations, see Common DC configuration for ACS850-04 drives application guide (3AUA0000073108 [English]). Electrical installation...

  • Page 65: Installation Of Optional Modules

    Installation of optional modules Optional modules such as fieldbus adapters, I/O extensions and encoder interfaces ordered using option codes (see Type designation key on page 26) are pre-installed at the factory. Instructions for installing additional modules into the slots on the JCU control unit (see page for the available slots) are presented below.

  • Page 66: Connecting The Control Cables

    Connecting the control cables Control connections to the JCU control unit XPOW Notes: +24VI External power input [Default setting with ACS850 standard 24 V DC, 1.6 A control program (Factory macro). See firmware manual for other macros.] XRO1, XRO2, XRO3 *Total maximum current: 200 mA Relay output RO1 [Ready] The wiring shown is for demonstrative...

  • Page 67: Jumpers

    Jumpers DI/DIO grounding selector (located between XD24 and XDI) – Determines whether the DIGND (ground for digital inputs DI1…DI5) floats, or if it is connected to DIOGND (ground for digital input DI6, and digital input/outputs DIO1 and DIO2). If DIGND floats, the common of DI1…DI5 (either GND or V ) should be connected to XD24:2.

  • Page 68: Di6 (Xdi:6) As A Thermistor Input

    DI6 (XDI:6) as a thermistor input 1…3 PTC sensors can be connected to this input for motor temperature measurement. One sensor Three sensors XDI:6 XDI:6 Motor Motor XD24:1 XD24:1 3.3 nF 3.3 nF > 630 V AC > 630 V AC Notes: •...

  • Page 69: Drive-To-Drive Link (Xd2D)

    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 70: Safe Torque Off (Xsto)

    Safe torque off (XSTO) For the drive to start, both connections (OUT1 to IN1, and OUT2 to IN2) must be closed. This is implemented by means of a safety switch and related wiring. See page By default, the terminal block has jumpers to close the circuit. Remove the jumpers before connecting an external Safe torque off circuitry to the drive.
  • Page 71 Mounting the clamp plate Routing the control cables 0.7 N·m Use shrink tubing or tape to (6.2 lbf·in) contain strands Run cables through the cover mounting bracket Remove outer jacket of cable at clamp to expose cable shield. Tighten clamp to 1.5 N·m (13 lbf·in) Electrical installation...
  • Page 72 Electrical installation...

  • Page 73: Installation Checklist

    The VAR (frames A and B) and EMC/VAR1/VAR2 (frames C and D) screws are removed if the drive is connected to an IT (ungrounded) or a corner grounded TN supply network. The capacitors are reformed if stored over one year (ask local ABB representative for more information).
  • Page 74 Check that... There are no power factor compensation capacitors in the motor cable. The external control connections to the JCU control unit are OK. There are no tools, foreign objects or dust from drilling inside the drive. The supply (input power) voltage cannot be applied to the output of the drive through a bypass connection.

  • Page 75: Start-Up

    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 76 Start-up...

  • Page 77: Maintenance

    Maintenance intervals The table below lists the routine maintenance intervals recommended by ABB. Consult a local ABB Service representative for more details. On the Internet, go to http://www.abb.com/drivesservices, select Drive Services, and Maintenance and Field Services.

  • Page 78: Heatsink

    Heatsink The heatsink fins pick up dust from the cooling air. The drive runs into overtemperature warnings and faults if the heatsink is not clean. In a normal environment, the heatsink should be checked annually, in a dusty environment more often.

  • Page 79: Cooling Fan

    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 80: Fan Replacement (Frames C And D)

    Fan replacement (Frames C and D) To remove the fan, release the retaining clip (arrowed) carefully using a screwdriver. Pull the fan holder out. Disconnect the fan cable. Carefully bend the clips on the fan holder to free the fan. Install the new fan in reverse order.

  • Page 81: Reforming The Capacitors

    The capacitors must be reformed if the drive has been stored for a year or more. See page for information on finding out the manufacturing date. For information on reforming the capacitors, contact your local ABB representative. Other maintenance actions Transferring the memory unit to a new drive module When a drive module is replaced, the parameter settings can be retained by transferring the memory unit from the defective drive module to the new module.
  • Page 82 Maintenance...

  • Page 83: Technical Data

    CE and other markings. Ratings Nominal ratings with 230 V AC supply Output ratings Input ratings Nominal No-overload use Light-overload use Heavy-duty use Drive type Frame ACS850-04… size -03A0-2 0.37 0.37 0.37 -03A6-2 0.55 0.75 0.55 0.75 0.37 -04A8-2 0.75...

  • Page 84: Nominal Ratings With 400 V Ac Supply

    Nominal ratings with 400 V AC supply Output ratings Input ratings No-overload Light-overload Heavy-duty Nominal Drive type Frame ACS850-04… size -03A0-5 0.75 -03A6-5 -04A8-5 -06A0-5 -08A0-5 11.2 10.5 -010A-5 10.5 13.5 -014A-5 16.5 13.0 11.0 -018A-5 16.8 14.0 -025A-5 –...

  • Page 85: Nominal Ratings With 500 V Ac Supply

    Note: 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 86: Ambient Temperature Derating

    The derated values are given in the tables below. Deratings with 230 V AC supply in low motor noise mode Output ratings Input ratings Nominal No-overload use Light-overload use Heavy-duty use Drive type Frame ACS850-04… size -03A0-2 0.37 0.25 0.25 0.25 -03A6-2 0.37 0.37 0.25...

  • Page 87: Deratings With 400 V Ac Supply In Low Motor Noise Mode

    Deratings with 400 V AC supply in low motor noise mode Output ratings Input ratings No-overload Light-overload Heavy-duty Nominal Drive type Frame ACS850-04… size -03A0-5 0.75 0.75 0.55 -03A6-5 0.75 -04A8-5 -06A0-5 -08A0-5 10.5 -010A-5 13.5 -014A-5 16.5 11.4 -018A-5 12.2...

  • Page 88: Deratings With 500 V Ac Supply In Low Motor Noise Mode

    Deratings with 500 V AC supply in low motor noise mode Output ratings Input ratings No-overload Light-overload Heavy-duty Nominal Drive type Frame ACS850-04… size -03A0-5 0.75 0.75 0.55 -03A6-5 0.75 -04A8-5 -06A0-5 -08A0-5 10.5 -010A-5 13.5 -014A-5 16.5 -018A-5 -025A-5 –...

  • Page 89: Cooling Characteristics, Noise Levels

    Cooling characteristics, noise levels Power loss Drive type Airflow Noise W (BTU/h) ACS850-04 level Load … /min) 100% -03A0-2 66 (226) 71 (244) 77 (264) 84 (287) 91 (312) 24 (14) -03A6-2 66 (226) 73 (247) 80 (272) 88 (300)

  • Page 90: Supply Cable Fuses

    Note: Fuses with a higher current rating must not be used. Cross-sectional IEC fuse UL fuse area of cable Input Drive type current Rated Rated ACS850-04… current Voltage Class current Voltage Class -03A0-2, -03A0-5 4.0* 1.5…4 16…12 -03A6-2, -03A6-5 6.0*...

  • Page 91: Ac Input (Supply) Connection

    Frames C and D: Screw lugs for 6…70 mm wire included. Suitable crimp lugs can be used instead. DC connection Voltage 243…356 V DC (ACS850-04-xxxx-2 drives) 436…743 V DC (ACS850-04-xxxx-5 drives) Ratings, fuse IEC fuse UL fuse recommendations Drive type...

  • Page 92: Motor Connection

    Motor connection Motor types Asynchronous induction motors, permanent magnet motors, ABB synchronous reluctance motors Frequency 0…500 Hz Current See section Ratings. Switching frequency 3 kHz (default) Maximum motor cable Frames A and B: 150 m (492 ft) * length Frames C and D: 300 m (984 ft) *...
  • Page 93 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. Filtering: 0.25 ms DIO1 can be configured as a As outputs: frequency input (0…16 kHz)

  • Page 94: Efficiency

    Isolation and grounding XPOW +24VI diagram XRO1…XRO3 XD24 +24VD DIGND +24VD DIOGND DIIL XDIO DIO1 DIO2 +VREF -VREF AGND AI1+ Common mode voltage AI1- AI2+ between channels AI2- ± 20 V AO1+ AO1- AO2+ AO2- XD2D BGND XSTO OUT1 OUT2 Ground Efficiency Approximately 98% at nominal power level...

  • Page 95: 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 Non-corner grounded TN and TT systems: 0 to 4000 m (13123 ft) above sea level.

  • Page 96: Applicable Standards

    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 97: Ce Marking

    CE marking A CE mark is attached to the drive to verify that the drive follows the provisions of the European Low Voltage, EMC and RoHS 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 98: Compliance With En 61800-3:2004

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

  • Page 99: Second Environment (Drive Of Category C3)

    (victim) Equipment 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 chapter Planning the electrical installation.

  • Page 100: Ul Marking

    UL marking The drive is cULus listed. UL checklist Input power connection – See section AC input (supply) connection on page 91. Disconnecting device (Disconnecting means) – See section Supply disconnecting device on page 43. Ambient conditions – The drive is to be used in a heated indoor controlled environment.

  • Page 101: Mains Chokes

    • reduces the r.m.s. input current • reduces supply disturbance and low-frequency interference • increases the allowed DC bus continuous power • ensures even current distribution in common DC configurations (see page 63). Selection table Mains chokes for the ACS850-04 Drive type Inductance Type ACS850-04…...

  • Page 102: Installation Guidelines

    • Keep the cable between the drive and the choke as short as possible. WARNING! The surface of the mains choke becomes hot when in use. Connection diagram AC supply DC supply CHK-xx mains choke – JFI-xx EMC filter (if present) ACS850-04 UDC+ UDC- Mains chokes...

  • Page 103: Emc Filters

    EMC filters What this chapter contains This chapter describes how to select and install EMC filters for the drive module. The chapter also contains the relevant technical data. When is an EMC filter required? The EMC product standard (EN 61800-3:2004) covers the specific EMC requirements stated for drives (tested with motor and cable) within the EU.

  • Page 104: Selection Table

    Selection table EMC filters for the ACS850-04 Filter type Drive type EN 61800-3:2004 EN 61800-3: 2004 ACS850-04… Category C3 Category C2 -03A0-2, -03A0-5 -03A6-2, -03A6-5 Option code +E200 -04A8-2, -04A8-5 JFI-02* (external filter JFI-A1) -06A0-2, -06A0-5 -08A0-2, -08A0-5 -010A-2, -010A-5...

  • Page 105: Jfi-A1/Jfi-B1 (Frame A/B, Category C3) Installation

    JFI-A1/JFI-B1 (Frame A/B, category C3) installation Installation guidelines • The filter is connected directly to the drive input connectors. • For optimal operation of the filter, the drive and the filter must be mounted on the same conductive surface. Connection diagram AC supply DC supply CHK-xx mains choke (if present)

  • Page 106: Mounting Procedures

    Mounting procedures JFI-A1 • Remove the UDC+/- and U1/V1/W1 terminal blocks (1), and the upper power cable clamp plate (2) from the drive. • Fasten the mounting bracket (3) to the drive module base with two screws (4). Tighten to 1.5 N·m (13 lbf·in). •...

  • Page 107: Jfi-B1

    JFI-B1 • Remove the UDC+/- and U1/V1/W1 terminal blocks (1), and the upper power cable clamp plate (2) from the drive. • Push the filter into the connectors. • Fasten the filter to the drive module base with two screws (3). Tighten to 1.5 N·m (13 lbf·in).

  • Page 108: Jfi-0X (Frames A

    JFI-0x (Frames A…D, category C2) installation Installation guidelines • If a mains choke is also installed, the EMC filter is connected between the mains choke and the drive module. See the connection diagram below. • For optimal operation of the filter, the drive and the filter must be mounted on the same conductive surface.

  • Page 109: Du/Dt And Common Mode Filtering

    The stress on motor insulation can be avoided by using optional ABB du/dt filters. du/dt filters also reduce bearing currents. Common mode filtering mainly reduces bearing currents.
  • Page 110 Motor type Nominal AC supply Requirement for voltage Motor insulation ABB du/dt and common mode filters, system insulated N-end motor bearings < 100 kW and frame size < IEC 315 < 134 hp and frame size < NEMA 500 ABB motors Random-wound M2_, M3_ <...

  • Page 111: And Am

    Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and AM_ Use the selection criteria given for non-ABB motors. Additional requirements for the braking applications When the motor brakes the machinery, the intermediate circuit DC voltage of the drive increases as well as the motor supply voltage by up to 20 percent.

  • Page 112: Technical Data

    9.5 (20.9) NOCH0120-60* 200 (7.87) 154 (6.06) 106 (4.17) 7.0 (15.4) *Dimensions given are per phase Degree of protection IP00 Common mode filters Contact your local ABB representative. Installation Follow the instructions included with the filters. du/dt and common mode filtering...

  • Page 113: Resistor Braking

    2. Calculate the continuous power based on the braking duty cycle. 3. Calculate the braking energy during the duty cycle. Pre-selected resistors are available from ABB as shown in the table on page 115. If the listed resistor is not sufficient for the application, a custom resistor can be selected within the limits imposed by the internal brake chopper of the ACS850-04.

  • Page 114: Chopper Data Table

    116. Chopper data table The ratings apply at an ambient temperature of 40 °C (104 °F). Internal brake chopper Drive type br10 br10 brcont brcont brmax ACS850-04… (kW) (kW) (kW) (kW) (kW) (kW) (kW) (ohm) -03A0-2 0.45 0.15...

  • Page 115: Resistor Selection Table

    The minimum allowed resistance of the brake resistor. Resistor selection table The ratings apply at an ambient temperature of 40°C (104°F). Example brake resistor Example brake resistor Drive type JBR-xx SACExxxxx ACS850-04… pulse Rcont Type Type (ohm) (kJ) (ohm) (kW)

  • Page 116: Resistor Installation And Wiring

    Resistor installation and wiring All resistors must be installed outside the drive module in a place where they are cooled sufficiently, do not block the airflow to other equipment, or dissipate hot air into the air inlets of other equipment. WARNING! The materials near the brake resistor must be non-flammable.
  • Page 117 WARNING! If the drive is equipped with a brake chopper but the chopper is not enabled by the parameter setting, the internal thermal protection of the drive against resistor overheating is not in use. In this case, the brake resistor must be disconnected.
  • Page 118 Resistor braking...

  • Page 119: Dimension Drawings

    Dimension drawings What this chapter contains Dimension drawings of the drive module and related accessories are shown below. The dimensions are given in millimetres and [inches]. Dimension drawings...

  • Page 120: Frame Size A

    Frame size A Dimension drawings...

  • Page 121: Frame Size B

    Frame size B Dimension drawings...

  • Page 122: Frame Size C

    Frame size C Dimension drawings...

  • Page 123: Frame Size D

    Frame size D Dimension drawings...

  • Page 124: Mains Chokes (Type Chk-0X)

    Mains chokes (type CHK-0x) 68906903 CHK-xx dimensions Choke type Parameter CHK-01 CHK-02 CHK-03 CHK-04 dim A mm (in.) 120 (4.72) 150 (5.91) 150 (5.91) 150 (5.91) dim B mm (in.) 146 (5.75) 175 (6.89) 175 (6.89) 175 (6.89) dim C mm (in.) 79 (3.11) 86 (3.39) 100 (3.94) 100 (3.94) dim D mm (in.) 77 (3.03) 105 (4.13) 105 (4.13) 105 (4.13)

  • Page 125: Emc Filters (Type Jfi-X1)

    EMC filters (type JFI-x1) JFI-A1 Dimension drawings...

  • Page 126: Jfi-B1

    JFI-B1 Dimension drawings...

  • Page 127: Emc Filters (Type Jfi-0X)

    EMC filters (type JFI-0x) Dimension drawings...
  • Page 128 JFI-xx dimensions Filter type Parameter JFI-02 JFI-03 JFI-05 JFI-07 Dim. A mm (in.) 250 (9.84) 250 (9.84) 250 (9.84) 270 (10.63) Dim. B mm (in.) 45 (1.77) 50 (1.97) 85 (3.35) 90 (3.54) Dim. C mm (in.) 70 (2.76) 85 (3.35) 90 (3.54) 150 (5.91) Dim.

  • Page 129: Brake Resistors (Type Jbr-Xx)

    Brake resistors (type JBR-xx) Dimension drawings...
  • Page 130 JBR-xx dimensions Resistor type Parameter JBR-01 JBR-03 JBR-04 JBR-05 JBR-06 Dim. A mm (in.) 295 (11.61) 340 (13.39) – – – Dim. B mm (in.) 155 (6.10) 200 (7.87) – – – Dim. C mm (in.) 125 (4.92) 170 (6.69) –...

  • Page 131: 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 132 Contact us www.abb.com/drives www.abb.com/drivespartners...

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