ABB ACS 600 Hardware Manual
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ABB ACS 600 Hardware Manual

Frequency converters 55 to 630 kw (75 to 700 hp)
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See also: User Manual , Installation Manual
Hardware Manual
ACS 600
This manual includes
ACS/ACC/ACP 604/607 Frequency Converters
• Safety
55 to 630 kW
• Installation
• Maintenance
(75 to 700 HP)
• Product Information
ACS 600

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Summary of Contents for ABB ACS 600

  • Page 1 Hardware Manual ACS 600 This manual includes ACS/ACC/ACP 604/607 Frequency Converters • Safety 55 to 630 kW • Installation • Maintenance (75 to 700 HP) • Product Information ACS 600...
  • Page 3 ACS 604, ACC 604 and ACP 604 frequency converter modules. In the text, they are collectively referred to as ACx 604/607. 3AFY 61201394 R0525 REV A EFFECTIVE: 5.10.1998 SUPERSEDES: 29.5.1998 Appendix B: 5.10.1998 © 1998 ABB Industry Oy. All Rights Reserved.
  • Page 5 Safety Instructions Overview This chapter states the safety instructions that must be followed when installing, operating and servicing the ACS/ACC/ACP 604/607. If neglected, physical injury and death may follow, or damage may occur to the frequency converter, the motor and driven equipment. The material in this chapter must be studied before attempting any work on, or with, the unit.
  • Page 6 Safety Instructions Installation and These safety instructions are intended for all work on the ACx 604/607. Ã Neglecting these instructions can cause physical injury and death. Maintenance Safety WARNING! All electrical installation and maintenance work on the ACx 600 should be carried out by qualified electricians. Do not attempt any work on a powered ACx 600.
  • Page 7 Parameter 30.17 (ACC: 30.11). The internal earth fault protective function is not in use in the 12-pulse supplied units. For ACS 62x units, refer to ACS 600 Power Extension Range Supplement or ACS 600 Converter Module Installation in User-defined Cabinet .
  • Page 8 The requirement of motor insulation level in ACx 600 frequency Requirement converter drive is given below. Motor Type Nominal Mains Voltage Motor Insulation Requirement < 500 V ABB Motors T‡hqh…qÃv †ˆyh‡v‚Ã†’ †‡r€ (manufactured from 525 V < U ≤ 690 V T‡hqh…qÃv †ˆyh‡v‚ÃhqÃqˆq‡Ãsvy‡r… beginning of 1998) ‚…...
  • Page 9 Safety Instructions Symbol Definition nominal mains voltage peak line to line voltage at motor terminals Ó Rise time Rise time is line to line voltage change rate at motor terminals (the interval during which the voltage changes from 10 % to 90 % of the whole voltage range) = 0.8 ·...
  • Page 10 If a contactor is used between the output of the ACx 600 and the motor with DTC control mode selected, the output voltage of the ACx 600 must be controlled to zero before the contactor is opened: ACS 600 units via parameter 21.3 (ACP: 10.4), choose COAST. If RAMP is selected, the output of the ACS/ACP 600 must be reduced to zero using Parameter 16.1 by giving zero V DC to the selected digital input.
  • Page 11 Safety Instructions Relay Contacts When used with inductive loads (relays, contactors, motors), the relay contacts of ACx 600 must be protected with varistors or RC networks (AC) or diodes (DC) against voltage transients. The protective components should not be installed at the NIOC board terminal block. The ACx 600 and adjoining equipment must be properly earthed.
  • Page 12 Safety Instructions Components Connected to Digital/ Analogue Inputs WARNING! IEC 664 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 ACx 600 can be implemented in three alternate ways:...
  • Page 13 Safety Instructions Cooling WARNING! The cooling air flows and space requirements must be fulfilled. Special attention must be paid to cooling if units are installed in confined spaces and user defined cabinets. CAUTION! The ACx 607 should only be transported on the original HrpuhvphyÃ...
  • Page 14 Safety Instructions ACx = ACS/ACC/ACP ACS/ACC/ACP 604/607 Frequency Converters...

  • Page 15: Table Of Contents

    7DEOH RI &RQWHQWV Safety Instructions Overview ..............iii CAUTION! .
  • Page 16 Chapter 4 – Installation Checklist Installation Checklist ............4-1 Chapter 5 –...
  • Page 17 Appendix B – ACx 607 Dimensional Drawings 68T68868QÃ%#%&ÃCh…qh…rÃHhˆhyà ‘‰...
  • Page 18 ‘‰v 68T68868QÃ%#%&ÃCh…qh…rÃHhˆhyÃ...

  • Page 19: Chapter 1 - Introduction

    For ACx 604 modules, see also Converter Module Installation in User- defined Cabinet . For types ACx 607-0400-3 and -0490-5/6 and up, see also ACS 600 Power Extension Range Supplement . The supplement covers dimensional drawings for the units and instructions that differ from those given in this manual.

  • Page 20: Acx 604/607 Type Code

    The meaning of main selections of ACx 604/607 type code characters 68‘Ã%#%&ÃU’ƒrÃ8‚qr is given in the table below. Not all selections are available for all types. More information on selections is in ACS 600 SingleDrive Ordering Information guide (code: 58977985, available on request). Character...

  • Page 21: Inquiries

    Refer to Braking Chopper and Cabling Direction Other Options Any inquiries about the product should be addressed to the local ABB D„ˆv…vr† representative, quoting the type code and the serial number of the unit. If the local ABB representative cannot be contacted, inquiries should be addressed to ABB Industry, Helsinki, Finland.
  • Page 22 Chapter 1 – Introduction ACS/ACC/ACP 604/607 Frequency Converters...

  • Page 23: Chapter 2 - Mechanical Installation

    Chapter 2 – Mechanical Installation See Appendix A – Technical Data for allowed operation conditions of the ACx 604/607. For installation of ACx 604 module in a cabinet refer to a supplement to this manual: Converter Module Installation in User- defined Cabinet .
  • Page 24 Chapter 2 – Mechanical Installation 3 holes 4 fastening hooks Figure 2-1 ACx 607 installation on floor. ACS/ACC/ACP 607 Frequency Converters...

  • Page 25: Chapter 3 - Electrical Installation

    Chapter 3 – Electrical Installation WARNING! The electrical installation described in this chapter should only be carried out by a qualified electrician. The Safety Instructions on the first pages of this manual must be followed. Negligence of these instructions can cause injury or death. Insulation Checks Every ACx 600 unit has been tested for insulation between main circuit and chassis (2500 V rms 50 Hz for 1 second) at the factory.

  • Page 26: Input Cable Protection

    Chapter 3 – Electrical Installation Input Cable Protection Normal slow fuses can be used to protect the input cable in case of a short circuit. (They do not protect the input bridge of ACx 600 in case of a short circuit.) Slow fuses must be dimensioned according to local safety regulations, appropriate mains voltage and the rated current of the ACx 600 (see Appendix A ).

  • Page 27: Alternative Power Cable Types

    Chapter 3 – Electrical Installation Alternative Power Cable Power cable types that can be used with ACx 600 are represented Types 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 <...

  • Page 28: Control Cables

    Never mix 24 VDC and 115 / 230 VAC signals in the same cable. Relay Cable The cable type ÖLFLEX (braided metallic screen, LAPPKABEL, Germany) has been tested and approved by ABB Industry. Encoder Cable (ACP 600) Min. 4 · 0.25 mm + 2 ·...

  • Page 29: Cable Routing

    Chapter 3 – Electrical Installation Control Panel Cable In remote use the cable connecting the Control Panel to the ACx 600 must not exceed 3 metres. The cable type tested and approved by ABB Industry is used in Control Panel option kits. Cable Routing The motor cable should be installed away from other cable routes.
  • Page 30 Chapter 3 – Electrical Installation A view of the recommended earthing, mains and motor cable Hhv†ÃH‚‡‚…Ãhqà connections of the ACx 607 is presented below. F denotes a 360 8‚‡…‚yÃ8hiyrà degrees earthing. 8‚rp‡v‚ Max 6 control cables ACx 607 Frequency Converter (option) EMC Line Filter NIOC/ NIOCP...

  • Page 31: Acx 607

    Chapter 3 – Electrical Installation WARNING! This work should only be carried out by a qualified electrician. The Safety Instructions on the first pages of this manual must be followed. Negligence of these instructions can cause injury or death. ACx 607 The mains and motor cables connect to the ACx 607 in the left part of the cabinet.
  • Page 32 Chapter 3 – Electrical Installation Cable shield PE terminal Strain relief EMC sleeve Strip this part of the cable Base plate Lead-through plate 9. Earth the other end of the mains cable screen at the distribution board. 10. Earth the motor cable screen 360 degrees on the motor side. 11.
  • Page 33 Adjust the setting if it does not correspond to the supply voltage. To access the transformer remove the front cover of the converter unit with the ABB logo. After adjusting the voltage put the plate back into its place.

  • Page 34: Control Cable Connecting Procedure

    Chapter 3 – Electrical Installation Control Cable To connect the control cables for ACx 607 carry out the following Connecting Procedure procedure: Side view Top view Lead-through plate EMI conductive cushions Holes for position screws Base plate 1. Loosen the lead-through plate position screws . Pull the two parts apart.
  • Page 35 Chapter 3 – Electrical Installation b. If the outer surface of the screen is covered with non-conductive material (figure below) Stripped cable Conductive surface of Stripped part covered the screen turned visible with copper foil Copper foil Cable screen Screened twisted pair Earthing wire - Cut the screen in the middle of the bare part.
  • Page 36 Chapter 3 – Electrical Installation Control Panel in Connect the Control Panel cable to terminal X19 of the NAMC-11, or Remote Use with NAMC-03 board to terminal X28 of the NIOC board (X300 of the NIOCP board). ACx 601/604 with NAMC-3 board and ACx 607 ACx 601/604 with NAMC-11 board NAMC-11 with NDCO NIOC...
  • Page 37 I/O Extension Modules W $ÃW Pulse Encoder Interface Module CH2* with ACS 600 W &ÃW Standard Application Program 5.0 CH1 with ACS 600 Crane W $ÃW Application Program 5.x Double Pulse Encoder Interface CH2* W &ÃW Module (for ACP 600 only)

  • Page 38: Connection Examples

    Consult adapter module manual. I/O Extension Module ACx 600 Pulse Encoder Module with NAMC NIOC ACS 600 Crane, System, Master/Follower and Template Application Programs NDCO R XD NIOC Terminal X23 The terminals for Not supported by ACP 600 the power supply connection vary.
  • Page 39 Chapter 3 – Electrical Installation Connection Examples Pulse Encoder Module (NTAC) with ACS 600 Standard Application Program ACS 600* NAMC NIOC NDCO NIOC Terminal X23 The terminals for * The ACP 600 supports the the power supply NTACP Double Pulse connection vary.
  • Page 40 Chapter 3 – Electrical Installation 3-16 ACS/ACC/ACP 604/607 Frequency Converters...

  • Page 41: Chapter 4 - Installation Checklist

    Chapter 4 – Installation Checklist Installation Checklist The ACx 600 mechanical and electrical installation should be checked before start-up. It is advisable to go through the checklist below together with another person. Study carefully the Safety Instructions on the first pages of this manual before attempting any work on, or with, the unit.
  • Page 42 Chapter 4 – Installation Checklist INSTALLATION CHECKLIST Check that control connections inside the frame are OK. Check that there are no tools or other foreign objects inside the cabinet. With bypass connection, check that mains voltage cannot be applied to the output of the ACx 600.

  • Page 43: Chapter 5 - Maintenance

    Capacitor failure is usually followed by a mains fuse failure or a Fault trip. Contact ABB if capacitor failure is suspected. Replacements are available from ABB. Do not attempt operation with other than ABB specified spare parts. Reforming Reform (re-age) spare part capacitors once a year according to ACS 600 Capacitor Reforming Guide (code: 64059629).
  • Page 44 Chapter 5 – Maintenance ACS/ACC/ACP 604/607 Frequency Converters...

  • Page 45: Appendix A - Acs/Acc/Acp 604/607 Technical Data

    Appendix A – ACS/ACC/ACP 604/607 Technical Data IEC Ratings The IEC ratings ratings for ACx 604 and ACx 607 with 50 Hz and 60 Hz supplies are below. ACx = ACS/ACC/ACP. The ACx 607 is housed in a Drives-MNS cabinet. The ACx 604 is to be installed in a cabinet by the user.
  • Page 46 Notes concerning Pump and Fan Use only ACS 604/607-0210-5 ACS 604/607-0260-5 ACS 604/607-0320-5 Pump and Fan rating is available for ACS 600 with Standard and ACS 604/607-0400-5 400 (335) Pump and Fan Control Application Programs. ( ) typically achieved motorpower with I...

  • Page 47: Nema Ratings

    Appendix A – ACS/ACC/ACP 604/607 Technical Data NEMA Ratings The NEMA ratings for ACS 604 and ACS 607 with 60 Hz supply are below. Symbols are described on previous page. Normal Use Heavy-duty Use Duty Cycle Duty Cycle Duty Cycle 1/10 min 1/10 min 2/15 s...

  • Page 48: Input Power Connection

    601-0005-3 to ACx 601-0016-3, ACx 601-0006-5 to ACx 601-0020-5 and ACx 601-0009-6 to ACx 601-0020-6, if the motor cable length exceeds 70 metres (230 ft), an ABB representative should be consulted. Bearings of over 90 kW (125 HP) Motors: Insulated bearing at non- driven end is recommended.

  • Page 49: Efficiency And Cooling

    At sites over 1000 m (3300 ft.) above sea level, the maximum output current is derated 1% for every additional 100 m (330 ft.). If the installation site is higher than 2000 m (6600 ft.) above sea level, please contact your local ABB distributor or office for further information.

  • Page 50: Example

    Appendix A – ACS/ACC/ACP 604/607 Technical Data Fuses ACx 604/607 Type Type Types DIN 43620 DIN 43653 Manufacturer Size Size ACx 60x-0100-3 105000 Bussmann 170M3819 170M3019 ACx 60x-0120-5 ACx 60x-0120-3 ACx 60x-0140-5 ACx 60x-0140-3 ACx 60x-0170-5 ACx 60x-0170-3 190000 Bussmann 170M5811 170M5011 ACx 60x-0210-5...

  • Page 51: Cable Entries

    Appendix A – ACS/ACC/ACP 604/607 Technical Data Cable Entries Input power and motor cable terminal wire size capabilities and tightening torques for the ACS/ACC/ACP 604/607 are in the table below. The capability is specified based on wire lug that the terminal accepts (according to DIN 46234 for copper cables and DIN 46329 for aluminium cables), cable cross section that will fit through the European lead-through plate hole, and maximum electrically needed...

  • Page 52: Terminal Sizes And Tightening Torques

    Appendix A – ACS/ACC/ACP 604/607 Technical Data Terminal Sizes and Input power and motor cable terminal wire size capabilities (per phase) Tightening Torques and tightening torques for the ACS/ACC/ACP 604/607 are below. For terms used see above. Mains Terminals Motor Terminals Earthing Terminals Cabinet (Frame)

  • Page 53: External Control Connection Diagrams

    NIOC board or through an optional terminal block. If an optional I/O terminal block is furnished, the control panel code (16th digit) of the ACS 600 type code will contain a 4 or 5. Refer to Chapter 2 for the ACS 600 type code description.

  • Page 54: Nioc Board

    Appendix A – ACS/ACC/ACP 604/607 Technical Data NIOC Board External control connections of NIOC board for ACS 600 with Standard Application Software (Factory Macro) are below. External control connections are different with other application macros and programs (see Firmware Manual ).

  • Page 55: Optional Terminal Block X2

    Appendix A – ACS/ACC/ACP 604/607 Technical Data Optional Terminal Block External connections to optional terminal block X2 for ACS 600 Standard Application Program (Factory Macro) are shown below. External control connections are different with other application macros and programs (see Firmware Manual ).

  • Page 56: Optional Terminal Block 2Tb

    Optional Terminal Block External connections to optional terminal block 2TB. This option is available only with ACS 600 Standard Application Program. External control connections with Factory Macro are shown below. Connections are different with other application macros (see Firmware Manual ).

  • Page 57: Niocp Board

    Appendix A – ACS/ACC/ACP 604/607 Technical Data NIOCP Board External control connections of ACP 600 with NIOCP board (and Speed Control Application Macro) are below. External control connections are different with other application macros (see Firmware Manual ). Terminal Block X1 Function +10 V Reference Voltage +10 VDC...

  • Page 58: Nioc And Niocp Board Specifications

    Appendix A – ACS/ACC/ACP 604/607 Technical Data NIOC and NIOCP Data of the external control connection boards of the ACS 600 product family are given below. Board Specifications ACS/ACC/ACP 600 ACP 600 NIOC-01 Board NIOCP-01 Board Analogue Inputs ACS 600: Two Programmable Differential Two Bipolar Differential Voltage Inputs: = 100 Ω...
  • Page 59 (+24 VDC): Short circuit proof, group isolated Filtering Time Constant: ≤ 100 µs Isolation Test Voltage: 500 VAC, 1 minute Input Updating Time: 12 ms (ACS 600), 44 ms (ACC 600), 4 ms (ACP 600) An external 24 VDC supply can be used instead of the internal supply.

  • Page 60: Encoder Signals

    Appendix A – ACS/ACC/ACP 604/607 Technical Data ACS/ACC/ACP 600 ACP 600 NIOC-01 Board NIOCP-01 Board Encoder Input One Encoder Input: 3 channel differential, +5 V encoder supply, frequency ≤ 200 kHz, supply cable resistance compensation. COMBICON connector, 15 pins. Meets the EIA standard RS 422.

  • Page 61: Enclosures, Space Requirements

    Appendix A – ACS/ACC/ACP 604/607 Technical Data Enclosures, Space The cabinets, degrees of protection and free space requirements of ACx 600 types are given below. Requirements Space above Space below Space on Space in ACx 600 Type Enclosure Degree of left/right front/back Protection...

  • Page 62: Cooling Air Flow Requirements

    Appendix A – ACS/ACC/ACP 604/607 Technical Data Cooling Air Flow Cooling air flow requirements are given below. Requirements ACx 60x Flow 60x = 604/607 ACx 60x-0100-3/0120-5/0100-6 ACx 60x-0120-3/0140-5/0120-6 ACx 60x-0140-3/0170-5/0140-6/0170-6 1640 ACx 60x-0170-3/0210-5/0210-6 1640 ACx 60x-0210-3/0260-5/0260-6 1640 ACx 60x-0260-3/0320-5/0320-6 1840 ACx 60x-0320-3/0400-5/0400-6 1840 ACx 607-0400-3/0490-5/0490-6...

  • Page 63: Dimensions And Weights (Acx 604

    Appendix A – ACS/ACC/ACP 604/607 Technical Data Dimensions and Dimensions and weights of the ACx 604s are given below. Weights (ACx 604) ACS 600 Height Width Depth Weight ACS 604 Type mm (in) mm (in) mm (in) kg (lbs) 0100-3 0120-5 0100-6 860 (33.86)

  • Page 64: Dimensions And Weights (Acx 607

    Appendix A – ACS/ACC/ACP 604/607 Technical Data Dimensions and Dimensions and weights of the ACx 607s are given below. Weights (ACx 607) Height Width Depth Weight ACS 607 Type mm (in) mm (in) mm (in) kg (lbs) 0100-3 0120-5 0100-6 2078 /2316 275/300...

  • Page 65: Braking Chopper Dimensions

    Appendix A – ACS/ACC/ACP 604/607 Technical Data Braking Chopper The widths of units with braking chopper are below. Dimensions Width with Width with Width with Width with Width with Width with Braking Braking Braking Braking Braking Braking ACS 607 Chopper Chopper and ACS 607 Chopper...

  • Page 66: Application Programs

    Appendix A – ACS/ACC/ACP 604/607 Technical Data Application Programs Various application programs are available for the ACS 600 frequency converters. Not all selections are available for all types. One application program at a time can be loaded in the memory of the frequency converter.

  • Page 67: Application Macros

    Master/Follower + Macros included in English (UK & Am), French, Spanish, selection B Portuguese System System application English (ACS 600 MultiDrive) Motion ACP 600: Torque Control, Speed English, German Control, Positioning, Synchronising Control ACP 600: Torque Control, Speed Control English, German...

  • Page 68: Protection Features

    Preprogrammed Warnings: ACS 600 temperature, Motor Identification Run, Drive Identification Number change, User Macro, Target position (ACP). Programmable Automatic Reset Functions (ACS 600 Standard Application Program only): after overcurrent, overvoltage, undervoltage and analogue input below minimum value Information Functions: ACx 600 control firmware package version, ACx 600 application program version, ACx 600 test date.

  • Page 69: Applicable Standards

    Appendix A – ACS/ACC/ACP 604/607 Technical Data Applicable Standards The ACS 600 complies with the following standards: • EN 60204-1: 1992 + Corr. 1993 (IEC 204-1). Safety of machinery. Electrical equipment of machines. Part 1: General requirements. Provisions for compliance: The final assembler of the machine is...

  • Page 70: Ce Marking

    2. The ACx 607 is installed with motor and control cables as specified in this manual (for types ACS/ACC 607-0400-3, -0490-3/5/6, -0610-3/5/6 and -0760-5/6 with power cables as specified in ACS 600 Power Extension Range Supplement ). Note: It is recommended to equip the ACx 600 with the EMC filtering if there is equipment sensitive to conducted emission connected to the same supply transformer as the ACx 600.
  • Page 71 The EMC filtering of the ACx 600 units is marked in the type code as follows. * du/dt Filters + EMC Filters, ** du/dt Filters + No EMC Filters, *** EMC Cabinet with EMC Filters. Type Code ACS 600 Type Character no. EMC Filter No EMC Filter...

  • Page 72: Machinery Directive

    600 V ACS 600 is suitable for use in a circuit capable of delivering not more than 65 kA rms symmetrical amperes at 480 V maximum (500 V units), and at 600 V maximum (690 V units).

  • Page 73: Equipment Warranty And Liability

    Equipment or part thereof or services which give rise to the Claim. All clauses of action against ABB arising out of or relating to the contract or the performance or breach hereof shall expire unless brought within one year of the time of accrual thereof.
  • Page 74 Appendix A – ACS/ACC/ACP 604/607 Technical Data Your local distributor or ABB office may hold different guarantee details, which are specified in the sales terms, conditions, or guarantee terms. These terms are available on request. If you have any questions concerning your ABB frequency converter, please contact the local distributor or ABB office.
  • Page 75 $SSHQGL[ % ± $&[  'LPHQVLRQDO 'UDZLQJV The following drawing package is effective from 5.10.1998. ACS/ACC/ACP 607 Frequency Converters...
  • Page 76 Appendix B – ACx 607 Dimensional Drawings ACS/ACC/ACP 607 Frequency Converters...
  • Page 94 ABB Industry Oy Drives P.O. Box 184 FIN-00381 HELSINKI FINLAND Telephone +358 10 22 2000 Telefax +358 10 22 22681...

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Acp 604Acc 604Acs 604Acs 607Acc 607Acp 607

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