ABB ACS800-01 Hardware Manual
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ABB ACS800-01 Hardware Manual

Drives (0.55 to 110 kw). drives (0.75 to 150 hp)
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ACS800
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ACS800-01 Drives (0.55 to 110 kW)
ACS800-U1 Drives (0.75 to 150 HP)

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Summary of Contents for ABB ACS800-01

  • Page 1 ACS800 Hardware Manual ACS800-01 Drives (0.55 to 110 kW) ACS800-U1 Drives (0.75 to 150 HP)

  • Page 2: Acs800 Single Drive Manuals

    ACS800 Single Drive Manuals HARDWARE MANUALS (appropriate manual is included in the delivery) ACS800-01/U1 Hardware Manual 0.55 to 110 kW (0.75 to 150 HP) 3AFE64382101 (English) ACS800-01/U1 Marine Supplement 3AFE 64291275 (English) ACS800-02/U2 Hardware Manual 90 to 500 kW (125 to 600 HP)
  • Page 3 ACS800-01 Drives 0.55 to 110 kW ACS800-U1 Drives 0.75 to 150 HP Hardware Manual 3AFE64382101 Rev E EN EFFECTIVE: 15.6.2004 ã 2004 ABB Oy. All Rights Reserved.

  • Page 5: Safety Instructions

    To which products this chapter applies This chapter applies to the ACS800-01/U1, the ACS800-02/U2 and the ACS800-04/ Use of warnings and notes There are two types of safety instructions throughout this manual: warnings and notes.

  • 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. Ignoring the instructions can cause physical injury or death. Only qualified electricians are allowed to install and maintain the drive. • Never work on the drive, motor cable or motor when main power is applied.

  • Page 7: Grounding

    (ACS800-02: 360° high frequency grounding of cable entries is not required at the drive end.) • Do not install a drive with EMC filter option +E202 or +E200 (available for ACS800-01 only) on an ungrounded power system or a high resistance- grounded (over 30 ohms) power system. Note: •...

  • Page 8: Fibre Optic Cables

    • ACS800-01: The drive is heavy. Do not lift it alone. Do not lift the unit by the front cover. Place the unit only on its back. ACS800-02, ACS800-04: The drive is heavy. Lift the drive by the lifting lugs only.

  • Page 9: Operation

    Operation These warnings are intended for all who plan the operation of the drive or operate the drive. Ignoring the instructions can cause physical injury or death or damage the equipment. Before adjusting the drive and putting it into service, make sure that the motor •...

  • Page 10: Permanent Magnet Motor

    Permanent magnet motor These are additional warnings concerning permanent magnet motor drives. WARNING! Do not work on the drive when the permanent magnet motor is rotating. Also, when the supply power is switched off and the inverter is stopped, a rotating permanent magnet motor feeds power to the intermediate circuit of the drive and the supply connections become live.

  • Page 11: Table Of Contents

    The ACS800-01/U1 ........
  • Page 12 Mains cable (AC line cable) short-circuit protection ....... .36 ACS800-01/U1, ACS800-02/U2 without enclosure extension and ACS800-04/U4 ..36 Drive AC fuses (ACS800-07/U7, and ACS800-02/U2 with enclosure extension) .
  • Page 13 Equipment connected to the motor cable ..........42 Installation of safety switches, contactors, connection boxes, etc.
  • Page 14 RMIO board specifications ............66 Analogue inputs .
  • Page 15 Cooling ..............84 Degrees of protection .
  • Page 16 Protection of frame sizes R2 to R5 (ACS800-01/U1) ....... . .

  • Page 17: About This Manual

    Technical data. The ACS800-01 is manufactured in frame sizes R2 to R6. Categorization according to the + code The instructions, technical data and dimensional drawings which concern only certain optional selections are marked with + codes, e.g. +E202. The options included in the drive can be identified from the + codes visible on the type designation label of the drive.

  • Page 18: Contents

    The ACS800-01/U1 describes the drive. Mechanical installation instructs how to place and mount the drive.

  • Page 19: Installation And Commissioning Flowchart

    If the converter has been non-operational for equipment are present and correct. more than one year, the converter DC link capacitors need to be reformed. Ask ABB for Only intact units may be started up. instructions. If the drive is about to be connected to an IT...

  • Page 20: Inquiries

    Inquiries Address any inquiries about the product to the local ABB representative, quoting the type code and the serial number of the unit. If the local ABB representative cannot be contacted, address inquiries to the manufacturing facility. About this manual...

  • Page 21: The Acs800-01/U1

    The ACS800-01/U1 What this chapter contains This chapter describes the operating principle and construction of the drive in short. The ACS800-01/U1 The ACS800-01/U1 is a wall mountable drive for controlling AC motors. Control panel CDP312R Heat sink Front cover Connection box...

  • Page 22: Type Code

    Type code The type code contains information on the specifications and configuration of the drive. The first digits from left express the basic configuration (e.g. ACS800-01- 0006-5). The optional selections are given thereafter, separated by + signs (e.g. +E202). The main selections are described below. Not all selections are available for all types.

  • Page 23: Main Circuit And Control

    AC voltage to DC voltage capacitor bank energy storage which stabilizes the intermediate circuit DC voltage six-pulse IGBT inverter converts the DC voltage to AC voltage and vice versa. The motor operation is controlled by switching the IGBTs. The ACS800-01/U1...

  • Page 24: Printed Circuit Boards

    Motor control The motor control is based on the Direct Torque Control (DTC) method. Two phase currents and DC link voltage are measured and used for the control. The third phase current is measured for earth fault protection. The ACS800-01/U1...

  • Page 25: Mechanical Installation

    Mechanical installation Unpacking the unit The drive is delivered in a box that also contains: • plastic bag containing: screws (M3), clamps and cable lugs (2 mm , M3) for grounding the control cable screens • connection box (screws, clamps and vibration dampers with +C131 included) •...

  • Page 26: Delivery Check

    Delivery check Check that there are no signs of damage. Before attempting installation and operation, check the information on the type designation label of the drive to verify that the unit is of the correct type. The label includes an IEC and NEMA rating, UL, C-UL, CSA and CE markings, a type code and a serial number, which allow individual recognition of each unit.

  • Page 27: Free Space Around The Unit

    Free space around the unit Required free space around the drive to enable cooling air flow, service and maintenance is shown below in millimetres and [inches]. When mounting IP 55 units above one another, leave 200 mm (7.9 in.) free space above and below the unit. 50 [2.0] 200 [7.9] 50 [2.0]...

  • Page 28: Mounting The Drive On The Wall

    IP 55 (UL type 12) marine applications (+C132) of frame sizes R4 to R6 See ACS800-01/U1 Marine Supplement [3AFE68291275 (English)]. Units with vibration dampers (+C131) See ACS800-01/U1 Vibration Damper Installation Guide [3AFE68295351 (English)]. UL 12 units Install the hood delivered with the drive 50 mm (2.0 in.) above the top of unit.

  • Page 29: Cabinet Installation

    Cabinet installation The required distance between parallel units is five millimetres (0.2 in.) in installations without the front cover. The cooling air entering the unit must not exceed +40 °C ( +104 °F) . Preventing cooling air recirculation Prevent air recirculation inside and outside the cabinet. Example AREA Main air flow out...

  • Page 30: Unit Above Another

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

  • Page 31: Planning The Electrical Installation

    Always follow local regulations. Note: If the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover. To which products this chapter applies...

  • Page 32: Protecting The Motor Insulation And Bearings

    The stress on motor insulation can be avoided by using optional ABB du/dt filters. du/dt filters also reduce bearing currents.

  • Page 33: Requirements Table

    Requirements table The following table shows how to select the motor insulation system and when an optional ABB du/dt filter, insulated N-end (non-driven end) motor bearings and ABB common mode filters are required. The motor manufacturer should be consulted regarding the construction of the motor insulation and additional requirements for explosion-safe (EX) motors.
  • Page 34 For motors with higher rated output than what is stated for the particular frame size in EN 50347 (2001) and for IP 23 motors, the requirements of ABB random-wound motor series M3AA, M3AP, M3BP are given below. For other motor types, see the Requirements table above.

  • Page 35: Permanent Magnet Synchronous Motor

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

  • Page 36: Thermal Overload And Short-Circuit Protection

    (see Technical Data). ACS800-01/U1, ACS800-02/U2 without enclosure extension and ACS800-04/U4 When placed at the distribution board, standard gG (US: CC or T for the ACS800- U1; T or L for the ACS800-U2 and ACS800-U4) fuses will protect the input cable in short-circuit situations, restrict drive damage and prevent damage to adjoining equipment in case of a short-circuit inside the drive.

  • Page 37: Circuit Breakers

    Circuit breakers Circuit breakers which have been tested by ABB with the ACS800 can be used. Fuses must be used with other circuit breakers. Contact your local ABB representative for approved breaker types and supply network characteristics. The protective characteristics of circuit breakers depend on the type, construction and settings of the breakers.

  • Page 38: Prevention Of Unexpected Start

    Prevention of Unexpected Start The drive can be equipped with an optional Prevention of Unexpected Start function according to standards IEC/EN 60204-1: 1997; ISO/DIS 14118: 2000 and EN 1037: 1996. The Prevention of Unexpected Start function disables the control voltage of the power semiconductors, thus preventing the inverter from generating the AC voltage required to rotate the motor.

  • Page 39: Selecting The Power Cables

    Selecting the power cables General rules Dimension the mains (input power) and motor cables according to local regulations: • The cable must be able to carry the drive load current. See chapter Technical data for the rated currents. ° • The cable must be rated for at least 70 C maximum permissible temperature of conductor in continuous use.

  • Page 40: Alternative Power Cable Types

    Alternative power cable types Power cable types that can be used with the drive are represented below. Recommended Symmetrical shielded cable: three phase conductors A separate PE conductor is required if the conductivity and a concentric or otherwise symmetrically of the cable shield is < 50 % of the conductivity of the constructed PE conductor, and a shield phase conductor.

  • Page 41: Additional Us Requirements

    Additional US requirements Type MC continuous corrugated aluminum armor cable with symmetrical grounds or shielded power cable must be used for the motor cables if metallic conduit is not used. For the North American market, 600 VAC cable is accepted for up to 500 VAC. 1000 VAC cable is required above 500 VAC (below 600 VAC).

  • Page 42: Equipment Connected To The Motor Cable

    Equipment connected to the motor cable Installation of safety switches, contactors, connection boxes, etc. To minimize the emission level when safety switches, contactors, connection boxes or similar equipment are installed in the motor cable (i.e. between the drive and the motor): •...

  • Page 43: Protecting The Relay Output Contacts And Attenuating Disturbances In Case Of Inductive Loads

    Protecting the relay output contacts and attenuating disturbances in case of inductive loads Inductive loads (relays, contactors, motors) cause voltage transients when switched off. The relay contacts on the RMIO board are protected with varistors (250 V) against overvoltage peaks. In spite of this, it is highly recommended to equip inductive loads with noise attenuating circuits [varistors, RC filters (AC) or diodes (DC)] in order to minimize the EMC emission at switch-off.

  • Page 44: Selecting The Control Cables

    Control panel cable In remote use, the cable connecting the control panel to the drive must not exceed 3 metres (10 ft). The cable type tested and approved by ABB is used in control panel option kits. Planning the electrical installation...

  • Page 45: Connection Of A Motor Temperature Sensor To The Drive I/O

    Connection of a motor temperature sensor to the drive I/O WARNING! IEC 60664 requires double or reinforced insulation between live parts and the surface of accessible parts of electrical equipment which are either non- conductive or conductive but not connected to the protective earth. To fulfil this requirement, the connection of a thermistor (and other similar components) to the digital inputs of the drive can be implemented in three alternate ways:...

  • Page 46: Control Cable Ducts

    A diagram of the cable routing is shown below. Motor cable Drive min 300 mm (12 in.) Power cable Input power cable Motor cable 90 ° min 200 mm (8 in.) min 500 mm (20 in.) Control cables Control cable ducts 24 V 230 V 24 V 230 V...

  • Page 47: 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 48: Checking The Insulation Of The Assembly

    Disconnect the EMC filter capacitors of selections +E202 and +E200 before connecting the drive to an ungrounded system. For detailed instructions on how to do this, please contact your local ABB distributor. WARNING! If a drive with EMC filter selection +E202 or +E200 is installed on an IT...

  • Page 49: Connecting The Power Cables

    Connecting the power cables Diagram Drive OUTPUT INPUT UDC+ V1 W1 U2 V2 W2 (PE) (PE) Optional brake For alternatives, see resistor Planning the electrical Motor installation: Disconnecting device (disconnecting means) 1), 2) Grounding of the motor cable shield at the motor end If shielded cable is used (not required but For minimum radio frequency interference: recommended), use a separate PE cable (1) or a...

  • Page 50: Conductor Stripping Lengths

    Conductor stripping lengths Strip the conductor ends as follows to fit them inside the power cable connection terminals. Frame size Stripping length R2, R3 0.39 R4, R5 0.63 1.10 Allowed wire sizes, tightening torques Technical data: Cable entries. Wall installed units (European version) Power cable installation procedure 1.
  • Page 51 Connection box (IP 21) Fastening hooks Back plate Fastening screws 360 degrees grounding clamp Grommet Motor cable entry Input cable entry Brake resistor cable entry Control cable entry Bottom plate Fasten the control cables between these plates with cable Cover ties Frame sizes R2 to R4 UDC+...
  • Page 52 Frame size R5 UDC+ UDC- Electrical installation...
  • Page 53 Frame size R6: Cable lug installation [16 to 70 mm (6 to 2/0 AWG) cables] Connection plate Isolate the ends of fastening screws the cable lugs with insulating tape or shrink tubing. Frame size R6: Cable terminal installation [95 to 185 mm (3/0 to 350 AWG)] cables a.

  • Page 54: Wall Installed Units (Us Version)

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

  • Page 55: Warning Sticker

    Wire size Compression lug Crimping tool kcmil/AWG Manufacturer Type Manufacturer Type No. of crimps Burndy YAV6C-L2 Burndy MY29-3 Ilsco CCL-6-38 Ilsco ILC-10 Burndy YA4C-L4BOX Burndy MY29-3 Ilsco CCL-4-38 Ilsco MT-25 Burndy YA2C-L4BOX Burndy MY29-3 Ilsco CRC-2 Ilsco IDT-12 Ilsco CCL-2-38 Ilsco MT-25 Burndy...

  • Page 56: Frame Size R5

    Protect the RMIO board terminals X25 to X27 against contact when input voltage exceeds 50 VAC. Frame size R5 Cover the power cable terminals as follows: 1. Cut holes for the installed cables into the clear plastic shroud. 2. Press the shroud onto the terminals. Removal of the shroud with a screw driver: Electrical installation...

  • Page 57: Frame Size R6

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

  • Page 58: Connecting The Control Cables

    Connecting the control cables Lead the cable through the control cable entry (1). Connect the control cables as described below. Connect the conductors to the appropriate detachable terminals of the RMIO board [refer to chapter Motor control and I/O board (RMIO)].
  • Page 59 Frame sizes R5 and R6 View of frame size R6 Control panel Optional module 2 Optional module 1 DDCS communication option module 3: RDCO Place the warning sticker here Control cable Detachable connection terminals (pull up) grounding: see section degrees grounding Electrical installation...

  • Page 60: Degrees Grounding

    360 degrees grounding Insulation Double-shielded cable Single-shielded cable When the outer surface of the shield is covered with non-conductive material • Strip the cable carefully (do not cut the grounding wire and the shield) • Turn the shield inside out to expose the conductive surface. •...

  • Page 61: Cabling Of I/O And Fieldbus Modules

    Cabling of I/O and fieldbus modules Module As short as possible Shield Note: The RDIO module does not include a terminal for cable shield grounding. Ground the pair cable shields here. Pulse encoder module cabling As short as possible Note1: If the encoder is of unisolated type, ground the encoder cable at the drive end only.

  • Page 62: Fastening The Control Cables And Covers

    Fastening the control cables and covers When all control cables are connected, fasten them together with cable ties. Units with a connection box: fasten the cables to the entry plate with cable ties. Units with a gland box: tighten the clamping nuts of the cable glands. Fasten the connection box cover.

  • Page 63: Motor Control And I/O Board (Rmio)

    Motor control and I/O board (RMIO) What this chapter contains This chapter shows • external control connections to the RMIO board for the ACS800 Standard Application Program (Factory Macro) • specifications of the inputs and outputs of the board. To which products this chapter applies This chapter applies to ACS800 units which employ the RMIO board.

  • Page 64: External Control Connections (Non-Us)

    External control connections (non-US) External control cable connections to the RMIO board for the ACS800 Standard Application Program (Factory Macro) are shown below. For external control connections of other application macros and programs, see the appropriate Firmware Manual. RMIO RMIO VREF- Reference voltage -10 VDC, 1 kohm <...

  • Page 65: External Control Connections (Us)

    External control connections (US) External control cable connections to the RMIO board for the ACS800 Standard Application Program (Factory Macro US version) are shown below. For external control connections of other application macros and programs, see the appropriate Firmware Manual. RMIO RMIO VREF-...

  • Page 66: Rmio Board Specifications

    RMIO board specifications Analogue inputs With Standard Application Program two programmable differential current inputs (0 mA / 4 mA ... 20 mA, R = 100 ohm) and one programmable differential voltage input (-10 V / 0 V / 2 V ... +10 V, R >...

  • Page 67: Relay Outputs

    Maximum continuous current 2 A rms Isolation test voltage 4 kVAC, 1 minute DDCS fibre optic link With optional communication adapter module RDCO. Protocol: DDCS (ABB Distributed Drives Communication System) 24 VDC power input Voltage 24 VDC ± 10 %...
  • Page 68 Isolation and grounding diagram (Test voltage: 500 V AC) VREF- AGND VREF+ AGND AI1+ Common mode AI1- voltage between AI2+ channels ±15 V AI2- AI3+ AI3- AO1+ AO1- AO2+ AO2- Jumper J1 settings: DGND1 All digital inputs share a common ground.

  • Page 69: Installation Checklist

    Installation checklist Checklist Check the mechanical and electrical installation of the drive before start-up. Go through the checklist below together with another person. Read the Safety instructions on the first pages of this manual before you work on the unit. Check MECHANICAL INSTALLATION The ambient operating conditions are allowed.
  • Page 70 Installation checklist...

  • Page 71: Maintenance

    Ignoring the safety instructions can cause injury or death. Maintenance intervals If installed in an appropriate environment, the drive requires very little maintenance. This table lists the routine maintenance intervals recommended by ABB. Maintenance Interval Instruction...

  • Page 72: Heatsink

    If the drive is operated in a critical part of a process, fan replacement is recommended once these symptoms start appearing. Replacement fans are available from ABB. Do not use other than ABB specified spare parts.

  • Page 73: Fan Replacement (R4)

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

  • Page 74: Fan Replacement (R5)

    Fan replacement (R5) 1. Undo the fastening screws of the swing-out frame. 2. Open the swing-out frame. 3. Disconnect the cable. 4. Undo the fastening screws of the fan. 5. Install the new fan in reverse order. Bottom view Maintenance...

  • Page 75: Fan Replacement (R6)

    Fan replacement (R6) To remove the fan, undo the fixing screws. Disconnect the cable. Install the new fan in reverse order. Bottom view Additional fan There is an additional cooling fan in all IP 55 units and most IP 21 units. However, there is no additional fan in the following IP 21 units: -0050-2 to -0070-2, -0003-3 to - 0005-3, -0070-3 to -0120-3, -0004-5 to -0006-5, -0100-5 to -0140-5.

  • Page 76: Replacement (R6)

    It is not possible to predict a capacitor failure. Capacitor failure is usually followed by a mains fuse failure or a fault trip. Contact ABB if capacitor failure is suspected. Replacements for frame size R4 and up are available from ABB. Do not use other than ABB specified spare parts.

  • Page 77: Technical Data

    CE and other markings and warranty policy. IEC ratings The IEC ratings for the ACS800-01 with 50 Hz and 60 Hz supplies are given below. The symbols are described below the table. ACS800-01 size...

  • Page 78: Symbols

    ACS800-01 size Nominal Light-overload Heavy-duty use Frame Air flow Heat overload ratings size dissipation cont.max cont.max Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V -0004-5 -0005-5 -0006-5 10.8 -0009-5 10.5 13.8...

  • Page 79: Sizing

    In altitudes from 1000 to 4000 m (3300 to 13123 ft) above sea level, the derating is 1 % for every 100 m (328 ft). For a more accurate derating, use the DriveSize PC tool. 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 80: Mains Cable Fuses

    Note 1: In multicable installations, install only one fuse per phase (not one fuse per conductor). Note 2: Larger fuses must not be used. Note 3: Fuses from other manufacturers can be used if they meet the ratings. ACS800-01 size Input Fuse...
  • Page 81 ACS800-01 size Input Fuse current Manufacturer Type IEC size Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V -0004-5 ABB Control OFAF000H10 -0005-5 ABB Control OFAF000H10 -0006-5 ABB Control OFAF000H10 -0009-5 10.0...

  • Page 82: Cable Types

    Cable types The table below gives copper and aluminium cable types for different load currents. Cable sizing is based on max. 9 cables laid on a cable ladder side by side, ambient temperature 30 °C, PVC insulation, surface temperature 70 °C (EN 60204-1 and IEC 60364-5-2/2001).

  • Page 83: Dimensions, Weights And Noise

    Dimensions, weights and noise H1 height with cable connection box, H2 height without cable connection box. Frame IP 21 IP 55 Noise size Width Depth Weight Height Width Depth Weight Input power connection Voltage (U 208/220/230/240 VAC 3-phase ± 10 % for 230 VAC units 380/400/415 VAC 3-phase ±...

  • Page 84: Efficiency

    Maximum recommended Sizing method Max. motor cable length motor cable length DTC control Scalar control according to I and I R2 to R3: 100 m (328 ft) R2: 150 m (492 ft) according to I R4 to R6: 300 m (984 ft) R3 to R6: 300 m (984 ft) cont.max ambient temperatures below...

  • Page 85: Ambient Conditions

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

  • Page 86: 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 50178 and EN 60204-1.

  • Page 87: Ce Marking

    CE marking A CE mark is attached to the drive to verify that the unit follows the provisions of the European Low Voltage and EMC Directives (Directive 73/23/EEC, as amended by 93/68/EEC and Directive 89/336/ EEC, as amended by 93/68/EEC). Definitions EMC stands for Electromagnetic Compatibility.

  • Page 88: Second Environment

    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 89: C-Tick" Marking

    “C-tick” marking A “C-tick” mark is attached to each drive in order to verify compliance with the relevant standard (IEC 61800-3 (1996) – Adjustable speed electrical power drive systems – Part 3: EMC product standard including specific test methods), mandated by the Trans-Tasman Electromagnetic Compatibility Scheme.

  • Page 90: Second Environment

    In no event shall the manufacturer, its suppliers or subcontractors be liable for special, indirect, incidental or consequential damages, losses or penalties. If you have any questions concerning your ABB drive, please contact the local distributor or ABB office. The technical data, information and specifications are valid at the time of printing. The manufacturer reserves the right to modifications without prior notice.

  • Page 91: Us Tables

    US tables NEMA ratings The NEMA ratings for the ACS800-U1 with 60 Hz supplies are given below. The symbols are described below the table. For sizing, derating and 50 Hz supplies, see ratings. ACS800-U1 size Normal use Heavy-duty use Frame Air flow Heat size...

  • Page 92: Symbols

    Overload may be limited to 5 % at high speeds (> 90 % speed) by the internal power limit of the drive. The limitation also depends on motor characteristics and network voltage. Overload may be limited to 40 % at high speeds (> 90 % speed) by the internal power limit of the drive.
  • Page 93 ACS800-U1 type Input Fuse current Manufacturer Type UL class Three-phase supply voltage 208 V, 220 V, 230 V or 240 V -0002-2 Bussmann JJS-10 -0003-2 Bussmann JJS-10 -0004-2 Bussmann JJS-15 -0006-2 Bussmann JJS-25 -0009-2 Bussmann JJS-30 -0011-2 Bussmann JJS-40 -0016-2 Bussmann JJS-50 -0020-2...

  • Page 94: Cable Types

    Cable types Cable sizing is based on NEC Table 310-16 for copper wires, 75 °C (167 °F) wire insulation at 40 °C (104 °F) ambient temperature. Not more than three current-carrying conductors in raceway or cable or earth (directly buried). For other conditions, dimension the cables according to local safety regulations, appropriate input voltage and the load current of the drive.

  • Page 95: Dimensions And Weights

    16.54 UL/CSA markings The ACS800-01 and ACS800-U1 units of UL type 1 are C-UL US listed and CSA marked. The UL and CSA markings are pending for units of UL type 12. The drive is suitable for use on a circuit capable of delivering not more than 65 kA rms symmetrical amperes at the drive nominal voltage (600 V maximum for 690 V units).
  • Page 96 Technical data...

  • Page 97: Dimensional Drawings

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

  • Page 98: Frame Size R2 (Ip 21, Ul Type 1)

    Frame size R2 (IP 21, UL type 1) Dimensional drawings...

  • Page 99: Frame Size R2 (Ip 55, Ul Type 12)

    Frame size R2 (IP 55, UL type 12) Dimensional drawings...

  • Page 100: Frame Size R3 (Ip 21, Ul Type 1)

    Frame size R3 (IP 21, UL type 1) Dimensional drawings...

  • Page 101: Frame Size R3 (Ip 55, Ul Type 12)

    Frame size R3 (IP 55, UL type 12) Dimensional drawings...

  • Page 102: Frame Size R4 (Ip 21, Ul Type 1)

    Frame size R4 (IP 21, UL type 1) Dimensional drawings...

  • Page 103: Frame Size R4 (Ip 55, Ul Type 12)

    Frame size R4 (IP 55, UL type 12) Dimensional drawings...

  • Page 104: Frame Size R5 (Ip 21, Ul Type 1)

    Frame size R5 (IP 21, UL type 1) Dimensional drawings...

  • Page 105: Frame Size R5 (Ip 55, Ul Type 12)

    Frame size R5 (IP 55, UL type 12) Dimensional drawings...

  • Page 106: Frame Size R6 (Ip 21, Ul Type 1)

    Frame size R6 (IP 21, UL type 1) Dimensional drawings...

  • Page 107: Frame Size R6 (Ip 55, Ul Type 12)

    Frame size R6 (IP 55, UL type 12) Dimensional drawings...

  • Page 108: Dimensional Drawings (Usa)

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

  • Page 109: Frame Size R2 (Ul Type 1, Ip 21)

    Frame size R2 (UL type 1, IP 21) Dimensional drawings...

  • Page 110: Frame Size R2 (Ul Type 12, Ip 54)

    Frame size R2 (UL type 12, IP 55) Dimensional drawings...

  • Page 111: Frame Size R3 (Ul Type 1, Ip 21)

    Frame size R3 (UL type 1, IP 21) Dimensional drawings...

  • Page 112: Frame Size R3 (Ul Type 12, Ip 54)

    Frame size R3 (UL type 12, IP 55) Dimensional drawings...

  • Page 113: Frame Size R4 (Ul Type 1, Ip 21)

    Frame size R4 (UL type 1, IP 21) Dimensional drawings...

  • Page 114: Frame Size R4 (Ul Type 12, Ip 54)

    Frame size R4 (UL type 12, IP 55) Dimensional drawings...

  • Page 115: Frame Size R5 (Ul Type 1, Ip 21)

    Frame size R5 (UL type 1, IP 21) Dimensional drawings...

  • Page 116: Frame Size R5 (Ul Type 12, Ip 54)

    Frame size R5 (UL type 12, IP 55) Dimensional drawings...

  • Page 117: Frame Size R6 (Ul Type 1, Ip 21)

    Frame size R6 (UL type 1, IP 21) Dimensional drawings...

  • Page 118: Frame Size R6 (Ul Type 12, Ip 54)

    Frame size R6 (UL type 12, IP 55) Dimensional drawings...

  • Page 119: Resistor Braking

    The chapter also contains the technical data. To which products this chapter applies This chapter applies to the ACS800-01/U1 (frame sizes R2 to R6), ACS800-02/U2 (frame sizes R7 and R8), ACS800-04/U4 (frame sizes R7 and R8) and ACS800-07/ U7 (frame sizes R6, R7 and R8).

  • Page 120: Optional Brake Chopper And Resistor(S) For The Acs800-01/U1

    ) is sufficient for the application (see step 3 above). Optional brake chopper and resistor(s) for the ACS800-01/U1 The nominal ratings for dimensiong the brake resistors for the ACS800-01 and ACS800-U1 are given below at an ambient temperature of 40 °C (104 °F). ACS 800-01 type...
  • Page 121 ACS 800-01 type Braking power of Brake resistor(s) ACS 800-U1 type the chopper and the drive Type brcont Rcont (kW) (ohm) (kJ) (kW) 400 V units -0003-3 SACE08RE44 -0004-3 SACE08RE44 -0005-3 SACE08RE44 -0006-3 SACE08RE44 -0009-3 SACE08RE44 -0011-3 SACE15RE22 -0016-3 SACE15RE22 -0020-3 SACE15RE22 -0025-3...

  • Page 122: Acs800-07/U7

    Optional brake chopper and resistor(s) for the ACS800-02/U2, ACS800-04/ 04M/U4 and ACS800-07/U7 The nominal ratings for dimensiong the brake resistors for the ACS800-02/U2, ACS800-04/04M/U4 and ACS800-07/U7 are given below at an ambient temperature of 40 °C (104 °F). ACS 800 type Frame Braking power of the chopper and the Brake resistor(s)
  • Page 123 ACS 800 type Frame Braking power of the chopper and the Brake resistor(s) size drive 5/60 s 10/60 s 30/60 s Type Rcont (ohm) (kJ) (kW) br10 br30 brcont (kW) (kW) (kW) (kW) 690 V units -0070-7 SAFUR90F575 8.00 1800 -0100-7 SAFUR80F500 6.00...

  • Page 124: Resistor Installation And Wiring

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

  • Page 125: Acs800-07/U7

    Note: If an external brake chopper (outside the drive module) is used, a main contactor is always required. A thermal switch (standard in ABB resistors) is required for safety reasons. The cable must be shielded and not longer than the resistor cable.

  • Page 126: Brake Circuit Commissioning

    OFF2 STOP. For the use of the brake resistor overload protection (parameters 27.02...27.05), consult an ABB representative. WARNING! If the drive is equipped with a brake chopper but the chopper is not enabled by parameter setting, the brake resistor must be disconnected because the protection against resistor overheating is then not in use.

  • Page 127: External +24 V Power Supply For The Rmio Board

    External +24 V power supply for the RMIO board What this chapter contains This chapter describes how to connect external +24 V power supply for the RMIO board. When to use External +24 V power supply for the RMIO board is recommended if •...

  • Page 128: Connecting +24 V External Power Supply

    Connecting +24 V external power supply 1. Break off the tab covering the +24 VDC power input connector with pliers. 2. Lift the connector upwards. 3. Disconnect the wires from the connector (keep the connector for later use). 4. Isolate the ends of the wires individually with insulating tape. 5.
  • Page 129 External +24 V power supply for the RMIO board...
  • Page 130 External +24 V power supply for the RMIO board...
  • Page 132 ABB Oy ABB Inc. AC Drives Automation Technologies P.O. Box 184 Drives & Motors FI-00381 HELSINKI 16250 West Glendale Drive FINLAND New Berlin, WI 53151 Telephone +358 10 22 11 +358 10 22 22681 Telephone 262 785-3200 Internet http://www.abb.com 800-HELP-365...

This manual is also suitable for:

Acs800-u1

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