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ABB ACQ810 Hardware Manual

Drive modules 200 to 400 kw, 250 to 600 hp
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ABB industrial drives
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ACQ810 drive modules
(200 to 400 kW, 250 to 600 hp)

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Summary of Contents for ABB ACQ810

  • Page 1 ABB industrial drives Hardware manual ACQ810 drive modules (200 to 400 kW, 250 to 600 hp)

  • Page 2: List Of Related Manuals

    List of related manuals Drive hardware manual and guide Code (English) ACQ810-04 hardware manual (200 to 400 kW) 3AUA0000055155 ACQ810-04 quick start-up guide 3AUA0000055159 Drive firmware manual ACQ810 standard pump control program firmware manual 3AUA0000055144 Option manuals and quides ACS-CP-U control panel IP54 mounting platform kit (+J410)
  • Page 3 Hardware manual ACQ810-04 drive modules (200 to 400 kW, 250 to 600 hp) Table of contents Safety instructions Mechanical installation Electrical installation Start-up © 2009 ABB Oy. All Rights Reserved. 3AUA0000055155 Rev A EFFECTIVE: 2009-09-15...

  • Page 5: Table Of Contents

    Table of contents List of related manuals ........... 2 1.
  • Page 6 HXR and AMA motors ..........55 ABB motors of types other than M2_, M3_, HX_ and AM_ ....55 Calculating the rise time and the peak line-to-line voltage .
  • Page 7 Selecting the power cables ..........56 General rules .
  • Page 8 Grounding the control unit ..........78 Connecting the control unit to the drive module .
  • Page 9 12. Technical data What this chapter contains ..........105 Ratings .
  • Page 10 Product training ............133 Providing feedback on ABB Drives manuals ....... . 133...

  • Page 11: Safety Instructions

    Safety instructions 11 Safety instructions What this chapter contains This chapter contains the safety instructions which you must follow when installing, operating and servicing the drive. If ignored, physical injury or death may follow, or damage may occur to the drive, motor or driven equipment. Read the safety instructions before you work on the unit.

  • Page 12: Safety In Installation And Maintenance

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

  • Page 13: Grounding

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

  • Page 14: General Safety

    14 Safety instructions General safety These instructions are intended for all who install and service the drive. WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment: • Handle the unit carefully. • The drive module is heavy 200 kg (441 lb). Lift it by the upper part only using the lifting lugs attached to the top of the unit.

  • Page 15: Fiber Optic Cables

    Safety instructions 15 Fiber optic cables WARNING! Ignoring the following instructions can cause equipment malfunction and damage to the fiber optic cables: • Handle the fiber optic cables with care. When unplugging optic cables, always grab the connector, not the cable itself. Do not touch the ends of the fibers with bare hands as the fiber is extremely sensitive to dirt.
  • Page 16 16 Safety instructions...

  • Page 17: Introduction To The Manual

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

  • Page 18: Related Manuals

    18 Introduction to the manual Operation principle and hardware description describes the drive module. Planning the cabinet installation guides in planning drive cabinets and installing the drive module into a user-defined cabinet. The chapter gives cabinet layout examples and free space requirements around the module for cooling.
  • Page 19 If the drive module 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. Check the installation site.

  • Page 20: Terms And Abbreviations

    20 Introduction to the manual Terms and abbreviations Term/Abbreviation Explanation Electromagnetic Compatibility Electromagnetic Interference FIO-11 Optional analogue I/O extension FIO-21 Optional analog and digital I/O extension FIO-31 Optional digital I/O extension with four relays FDNA-0x Optional DeviceNet™ adapter FENA-0x Optional Ethernet/IP™ adapter FLON-0x Optional LonWorks®...

  • Page 21: Operation Principle And Hardware Description

    Operation principle and hardware description 21 Operation principle and hardware description What this chapter contains This chapter describes the operating principle and construction of the drive module in short. Product overview The ACQ850-04 is a drive module for controlling asynchronous AC induction motors for water and waste water applications.
  • Page 22 22 Operation principle and hardware description The main circuit of the drive module is shown below. ACQ810-04 Capacitor bank Rectifier Inverter AC supply Motor output R- UDC+ UDC- This table describes the operation of the main circuit in short. Component...

  • Page 23: Layout

    Operation principle and hardware description 23 Layout The components of the standard unit are shown below. Cables going to the JCU Control Drive module Unit and APOW board are coiled on Fastening points the top of the module. Lifting lug Input cable terminals Fastening points Fastening points...
  • Page 24 24 Operation principle and hardware description The control unit layout is shown below (cover assembly and protective coverings of the slots removed). External 24 V power input Relay outputs +24VD Digital inputs Slots 1 for optional I/O extensions Digital input/outputs Analog inputs Analog outputs Drive-to-drive link...

  • Page 25: Alternative Output Busbar Configurations

    DC busbars on the left-hand side. The output busbars can also be fastened on the short back side of the module. For more information, contact your local ABB representative. Output busbars on the short side of...

  • Page 26: Component Placement

    26 Operation principle and hardware description Component placement The component layout stickers of the drive module are shown below. The stickers show all possible components. Not all of them are present in each delivery or described here. Components that need to be changed regularly are listed below: Designation Component Cooling fan...

  • Page 27: Power Connections And Control Interfaces

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

  • Page 28: Cables For Connecting The Control Unit To The Drive Module And Control Panel

    28 Operation principle and hardware description Cables for connecting the control unit to the drive module and control panel The cables connecting the drive module and control panel to the control unit are shown below. See section Connecting the control unit to the drive module, page for the actual connections.

  • Page 29: Type Designation Key

    Type designation key The type designation contains information on the specifications and configuration of the drive module. The first digits from left express the basic configuration eg, ACQ810-04- 477A-4. The optional selections are given thereafter, separated by plus signs eg, +L519.
  • Page 30 30 Operation principle and hardware description...

  • Page 31: Planning The Cabinet Installation

    Note: The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations.

  • Page 32: Planning The Layout Of The Cabinet

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

  • Page 33: Layout Examples, Door Open

    Planning the cabinet installation 33 Layout examples, door open Layout examples for IP22 and IP54 cabinets are shown below IP54 IP22 1 Supporting frame of the cabinet 2 Air baffles that separate the cool and hot areas (leak-proof lead-throughs) 3 Input power cable including the protective conductors to cabinet grounding (PE) 4 Disconnector and fuses...

  • Page 34: Arranging The Grounding Inside The Cabinet

    WARNING! Do not fasten the cabinet by electric welding if the drive module is already installed inside the cabinet. ABB does not assume any liability for damages caused by electric welding as the welding circuit may damage electronic...

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

    Planning the cabinet installation 35 Planning the cabinet placement on a cable channel Note the following when planning to place the cabinet on a cable channel: • The cabinet structure must be sturdy enough. If the whole cabinet base will not be supported from below, the cabinet weight must lie on the sections that the floor carries.
  • Page 36 36 Planning the cabinet installation • 360° high frequency grounding of the motor cable shields at their entries is recommended. The grounding can be implemented by a knitted wire mesh screening as shown below. Bare cable shield Cable ties Knitted wire mesh Lead-through plate Cable Cabinet bottom plate...

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

    Planning the cabinet installation 37 Planning the grounding of the cable shields at the cabinet lead-through Follow the principle shown in the figure below when planning the grounding of the cable shields at the cabinet lead-through. To power terminals Cable shield PE terminal of the cabinet or drive module...
  • Page 38 38 Planning the cabinet installation • The cabinet must have enough free space for the components to ensure sufficient cooling. Observe the minimum clearances given for each component. For the required free space around the drive module, see page 39. •...

  • Page 39: Preventing The Recirculation Of Hot Air

    Planning the cabinet installation 39 Preventing the recirculation of hot air Vertical air baffle A - A Air flow out Drive module Horizontal air baffle Drive module Air flow in max. 40°C (104 °F) Drive cubicle from side Drive cubicle from above Prevention the air recirculation 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.

  • Page 40: Free Space At Top With High Air Inlet Gratings In The Cabinet Door

    40 Planning the cabinet installation Free space at top with high air inlet gratings in the cabinet door The required free space at the top of the module is shown below when the air inlet gratings in the cabinet door are as high as the grating of the module. See also page 41. Air outlet on the Air outlet in the cabinet cabinet roof...

  • Page 41: Free Space At The Side And Front Of The Drive Module

    • 0 mm (0 in.) with air inlets as high as the grating in the module 1120 mm (44 in.) • 150 mm (5.91 in.) with air inlets at the lower part of the cabinet only. No extra space is needed at the back. Other installation positions Contact your local ABB representative.

  • Page 42: Planning The Placement Of The Control Panel

    42 Planning the cabinet installation Planning the placement of the control panel Note the following alternatives when planning the placement of the control panel: • The control panel can be snapped on the control unit. See page 23. • The control panel can be mounted onto the cabinet door using the control panel mounting kit (+J410).

  • Page 43: Mechanical Installation

    Mechanical installation 43 Mechanical installation What this chapter contains This chapter describes how to install the drive module into a cabinet.

  • Page 44: Safety

    44 Mechanical installation Safety WARNING! The drive module is heavy 200 kg (441 lb). Lift it by the upper part only using the lifting lugs attached to the top of the unit. The lower part will be deformed from lifting. Do not remove the pedestal before lifting. Do not tilt the drive.

  • Page 45: Moving And Unpacking The Unit

    Mechanical installation 45 Moving and unpacking the unit Move the transport package by pallet truck to the installation site. The layout of the transport package is shown below. Part no. Description Drive module with factory installed options and multilingual residual voltage warning sticker Output cable terminals with fastening screws Floor fastening brackets and PE...

  • Page 46: Attaching The Warning Stickers

    46 Mechanical installation Attaching the warning stickers Attach the residual voltage warning sticker of the local language onto the drive module front cover. Fastening the cable lug terminals to the output busbars 1. Fasten the grounding terminals to the long side plates of the pedestal with screws. 2.
  • Page 47 Mechanical installation 47 M10x25 M10x20 M10x25 Tightening torques: M10: 30...44 N·m (22...32 lbf·ft) M12: 50...75 N·m (37...55 lbf·ft) 2 pcs WARNING! Fasten the output busbars to the insulating supports with M10x20 screws when no cable lug terminal is connected, but with M10x25 screws when a cable lug terminal is connected as well.

  • Page 48: Fastening The Drive Module To The Cabinet Base

    48 Mechanical installation Fastening the drive module to the cabinet base 1. Fasten the front fastening bracket to the drive module pedestal with two screws. 2. Fasten the back fastening bracket onto the cabinet base with two screws. 3. Place the drive module on the cabinet base and push it so that the tabs of the fastening bracket enter the slots in the drive module pedestal.

  • Page 49: Installing The Drive Control Unit

    Mechanical installation 49 Installing the drive control unit The drive control unit can be fastened on a mounting plate through the fastening holes in its back or by using a DIN rail. The following drawings show the control unit with front cover but units without covers are installed in the same way.

  • Page 50: Vertical Din Rail Mounting

    50 Mechanical installation Vertical DIN rail mounting 1. Fasten the latch (A) to the back of the control unit with four screws. 2. Click the control unit to the rail as shown below (B). 3aua0000038989 Horizontal DIN rail mounting 1. Fasten the latches (A) to the back of the control unit with four screws. 2.

  • Page 51: Planning The Electrical Installation

    Note: The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.

  • Page 52: European Union

    52 Planning the electrical installation European Union To meet the European Union Directives, according to standard EN 60204-1, Safety of Machinery, the disconnecting device must be one of the following types: • switch-disconnector of utilization category AC-23B (EN 60947-3) • disconnector that has an auxiliary contact that in all cases causes switching devices to break the load circuit before the opening of the main contacts of the disconnector (EN 60947-3)

  • Page 53: Requirements Table

    440 V · 1.35 · 2 = 1190 V. Check that the motor insulation system withstands this voltage. 6. Use insulated N-end (non-drive end) bearings and output filters from ABB according to Requirements table below.

  • Page 54: Explosion-Safe (Ex) Motors

    54 Planning the electrical installation Motor Nominal AC line Requirement for type voltage Motor ABB du/dt filter, insulated N-end bearing and ABB common mode insulation filter system < 100 kW 100 kW < P < 350 kW > 350 kW frame size >...

  • Page 55: High-Output Motors And Ip 23 Motors

    For motors with higher rated output than what is stated for the particular frame size in EN 50347 (2001) and for IP23 motors, the requirements of ABB random-wound motor series (for example M3AA, M3AP, M3BP) are given below. For non-ABB motor types, see the Requirements table above.

  • Page 56: Sine Filters

    56 Planning the electrical installation Sine filters Sine filters protect the motor insulation system. Therefore, du/dt filter can be replaced with a sine filter. The peak phase-to-phase voltage with the sine filter is approximately 1.5 · U Selecting the power cables General rules Dimension the input power and motor cables according to local regulations: •...

  • Page 57: Typical Power Cable Sizes

    Planning the electrical installation 57 Typical power cable sizes 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, three ladder type trays one on top of the other, ambient temperature 30 °C, PVC insulation, surface temperature 70 °C (EN 60204-1 and IEC 60364-5-52/2001).

  • Page 58: Alternative Power Cable Types

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

  • Page 59: Conduit

    Planning the electrical installation 59 Conduit Couple separate parts of a conduit together: bridge the joints with a ground conductor bonded to the conduit on each side of the joint. Bond the conduits also to the drive enclosure and motor frame. Use separate conduits for input power, motor, brake resistor, and control wiring.

  • Page 60: Relay Cable Type

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

  • Page 61: Separate Control Cable Ducts

    Planning the electrical installation 61 Separate control cable ducts 230 V 230 V (120 V) (120 V) 24 V 24 V Not allowed unless the 24 V cable is Lead 24 V and 230 V (120 V) control cables in separate ducts inside the insulated for 230 V (120 V) or insulated cabinet.

  • Page 62: Implementing Thermal Overload And Short-Circuit Protection

    2. Circuit breakers which have been tested by ABB with the drive can be used. Fuses must be used with other circuit breakers. Contact your local ABB representative for the approved breaker types and supply network characteristics.

  • Page 63: Protecting The Motor Against Thermal Overload

    Planning the electrical installation 63 WARNING! If the drive is connected to multiple motors, a separate thermal overload switch or a circuit breaker must be used for protecting each cable and motor. These devices may require a separate fuse to cut off the short-circuit current.

  • Page 64: Implementing The Safe Torque Off Function

    (see diagram below). By using this function, short-time operations (like cleaning) and/or maintenance work on non-electrical parts of the machinery can be performed without switching off the power supply to the drive. Safe torque off ACQ810-04 Activation switch connection on JCU XSTO:1...

  • Page 65: Implementing The Power-Loss Ride-Through Function

    Planning the electrical installation 65 Implementing the Power-loss ride-through function The Power-loss ride-through function is activated when parameter 47.02 Undervolt ctrl is set to Enable (default in Standard pump control program). Note: If the drive is equipped with a line contactor, it opens in a power loss and must be closed again by a time relay.

  • Page 66: Implementing A Bypass Connection

    66 Planning the electrical installation Alternative 2: When you have selected to use the default motor control mode (DTC) and motor ramp stop in the drive, open the contactor as follows: 1. Give a stop command to the drive. 2. Wait until the drive decelerates the motor to zero speed. 3.

  • Page 67: Protecting The Contacts Of Relay Outputs

    Planning the electrical installation 67 An example bypass connection is shown below. Switch Description Drive main contactor on/off control Motor power supply selection (drive or direct on line) Start when motor is connected on line Stop when motor is connected direct on line WARNING! Never connect the supply power to the drive output terminals U2, V2 and W2.

  • Page 68: Connecting A Motor Temperature Sensor To The Drive I/O

    68 Planning the electrical installation Install the protective component as close to the inductive load as possible. Do not install protective components at the relay outputs. Varistor 230 VAC Relay output RC filter 230 VAC Relay output Diode 24 VDC Relay output Connecting a motor temperature sensor to the drive I/O WARNING! IEC 60664 requires double or reinforced insulation between live parts...

  • Page 69: Example Circuit Diagram

    Planning the electrical installation 69 Example circuit diagram See page 129.
  • Page 70 70 Planning the electrical installation...

  • Page 71: Electrical Installation

    Electrical installation 71 Electrical installation What this chapter contains This chapter instructs in the cabling of the drive. Warnings WARNING! Only qualified electricians are allowed to carry out the work described in this chapter. Follow the Safety instructions on the first pages of this manual. Ignoring the safety instructions can cause physical injury or death.

  • Page 72: Motor And Motor Cable

    Earth conductor using a measuring voltage of 500 V DC. The insulation resistance of an ABB motor must exceed 100 Mohm (reference value at 25 °C or 77 °F). For the insulation resistance of other motors, please consult the manufacturer’s instructions.

  • Page 73: Connecting The Power Cables

    Electrical installation 73 Connecting the power cables Connection diagram ACQ810-04 OUTPUT INPUT UDC+ V1 W1 V2 W2 (PE) (PE) Motor For alternatives, see section Selecting the supply disconnecting device (disconnecting means) on page If shielded cable is used (not required but recommended) and the conductivity of the shield is < 50% of the conductivity of the phase conductor, use a separate PE cable (2) or a cable with a grounding conductor (3).

  • Page 74: Input Cable Connection Procedure

    74 Electrical installation Input cable connection procedure Connect the input cable phase conductors to the drive module terminals U1, V1 and W1 and the PE conductor to the PE terminal. Connect the twisted shield of the input cable to the PE terminal even if it is not used as the PE conductor. Removing the protective covering The protective covering on top of the drive module prevents dust from borings and grindings from entering the module when installing.

  • Page 75: Motor Cable Connection Procedure

    Electrical installation 75 Motor cable connection procedure 1. Connect the twisted shield of the motor cable to the grounding terminal with a cable lug. 2. Connect the phase conductors to the cable lug terminals U2, V2 and W2. V2 U2 It is recommended to ground the motor cable shield 360°...

  • Page 76: Dc Connection

    The UDC+ and UDC– terminals are intended for common DC configurations of a number of drives, allowing regenerative energy from one drive to be utilized by the other drives in motoring mode. Contact your local ABB representative for further instructions. Checking the settings of the cooling fan transformer The voltage transformer of the cooling fan is located at the top right-hand corner of the drive module.

  • Page 77: Removing The Cover Assembly

    Electrical installation 77 Removing the cover assembly The cover assembly needs to be removed before the installation of optional modules and the connection of control cabling. Follow this procedure to remove the cover assembly. The numbers refer to the illustrations below. •...

  • Page 78: Fastening The Control Cable Clamp Plate

    78 Electrical installation Fastening the control cable clamp plate Fasten the control cable clamp plate either to the top or base of the control unit with four screws as shown below. 0.7 N·m (6.2 lbf·in) Grounding the control unit If the control unit is not grounded through DIN rail mounting, connect the APOW cable grounding wire to the grounding terminal at the back top or bottom of the control unit.

  • Page 79: Connecting The Control Unit To The Drive Module

    Electrical installation 79 Connecting the control unit to the drive module Connect the control unit to the drive module as follows. WARNING! Handle the fiber optic cables with care. When unplugging optic cables, always grab the connector, not the cable itself. Do not touch the ends of the fibers with bare hands as the fiber is extremely sensitive to dirt.

  • Page 80: Connecting The Control Cables

    80 Electrical installation 2. Insert the fiber optic cables to the JRIB board terminals. 3. Connect the power supply cable coming from the drive module to the cable connected to the JRIB board terminals. APOW board JINT board JRIB board Connection table APOW JRIB...

  • Page 81: Default I/O Connection Diagram

    Electrical installation 81 Default I/O connection diagram XPOW Notes: External power input +24VI […] denotes default setting with ACQ810 24 V DC, 1.6 A standard pump control program (Factory XRO1, XRO2 defs macro). See Firmware manual for Relay output RO1 [Ready] other macros.

  • Page 82: Jumpers

    82 Electrical installation Jumpers DI/DIO grounding selector (located between XD24 and XDI) – Determines whether the DIGND (ground for digital inputs DI1…DI4) floats, or if it is connected to DIOGND (ground for DI5 DIO1 and DIO2). See the JCU isolation and grounding diagram on page 115. If DIGND floats, the common of digital inputs DI1…DI4 should be connected to XD24:2.

  • Page 83: External Power Supply For The Jcu Control Unit (Xpow)

    Electrical installation 83 External power supply for the JCU Control Unit (XPOW) External +24 V (minimum 1.6 A) power supply for the control unit can be connected to terminal block XPOW. Using an external supply is recommended if • the application requires fast start after connecting the drive to the main supply •...

  • Page 84: Start Interlock (Xdi:a)

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

  • Page 85: Safe Torque Off (Xsto)

    Electrical installation 85 Safe torque off (XSTO) For the drive to start, both connections (OUT1 to IN1, and OUT2 to IN2) must be closed. 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. See page 64. Control cable connection procedure See the cable routing on page and connect the control cables as follows:...

  • Page 86: Routing The Control Cables

    86 Electrical installation Routing the control cables Use shrink tubing or tape to 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)

  • Page 87: Connecting A Pc

    Electrical installation 87 Connecting a PC Connect the PC to connector X7 on the control unit (see page 24) or to the connector in the control panel holder (see page 25). Installing optional modules Mechanical installation Optional modules such as a fieldbus adapters, an I/O extensions and the pulse encoder interfaces are inserted in the optional module slot on the control unit.
  • Page 88 88 Electrical installation...

  • Page 89: Installation Checklist

    Installation checklist 89 Installation checklist What this chapter contains This chapter contains a list for checking the mechanical and electrical installation of the drive. Go through the checklists below together with another person. Follow the Safety instructions on the first pages of this manual. Mechanical installation Cabinet construction Checks for cabinet construction are listed below.

  • Page 90: Instrumentation, Busbars And Cabling

    90 Installation checklist Instrumentation, busbars and cabling Checks for instrumentation, busbars, cabling, clearances and creepage distances are listed below. For more information, see chapter Planning the electrical installation. Instrumentation Type and number of option modules and other equipment is correct. Option modules and other equipment are not damaged.

  • Page 91: Groundings And Protection

    Electrical installation. Check The capacitors are reformed if stored over one year (ask local ABB representative for more information). The drive is grounded properly: 1) proper and properly tightenened PE connector, 2) proper galvanic connection between drive frame and cabinet (fastening points are unpainted).

  • Page 92: Cooling And Driven Equipment

    92 Installation checklist Check The supply (input power) voltage cannot be applied to the output of the drive through a bypass connection. Motor connection box and other covers are in place. Cooling and driven equipment Checks for cooling conditions and motor and driven equipment before start-up are listed below.

  • Page 93: Start-Up

    Start-up 93 Start-up What this chapter contains This chapter describes the start-up procedure of the drive. Start-up procedure Set-up of the drive program according to the start-up instructions given in the Quick start- up guide or Firmware manual. Perform the start-up tasks instructed by the cabinet-installer of the drive module.
  • Page 94 94 Start-up...

  • Page 95: Fault Tracing

    Fault tracing 95 Fault tracing What this chapter contains This chapter describes the fault tracing possibilities of the drive. LEDs This table describes LEDs of the drive module. Where When the LED is lit JINT board V204 (green) +5 V voltage of the board is OK. V309 (red) Not in use.
  • Page 96 96 Fault tracing...

  • Page 97: Maintenance

    What this chapter contains This chapter contains preventive maintenance instructions. Maintenance intervals If installed in an appropriate environment, the drive requires very little maintenance. This table lists the routine maintenance intervals recommended by ABB. Interval Maintenance Instruction Every year when stored...

  • Page 98: Cabinet

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

  • Page 99: Replacing The Cooling Fan Of The Module

    Maintenance 99 Replacing the cooling fan of the module WARNING! Follow the safety instructions, page 12. Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Remove the front cover. 2. Disconnect the fan capacitor and power supply wires. 3.

  • Page 100: Replacing The Drive Module

    100 Maintenance Replacing the drive module The drive module can be replaced by disconnecting the pedestal and busbars connected to it from the drive module and leaving the pedestal and busbars into the cabinet. Proceed as follows: WARNING! Follow the safety instructions, page 12. Ignoring the instructions can cause physical injury or death, or damage to the equipment.
  • Page 101 M6×16 combi, 8 N·m (6 lbf·ft) M10×25 combi, 30 N·m (22 lbf·ft) Pedestal when the module is removed Note: A drive module trolley is available from ABB. The trolley helps in removing heavy drive modules from a cabinet and in replacing the module.

  • Page 102: Capacitors

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

  • Page 103: Replacing The Capacitor Pack

    Maintenance 103 Replacing the capacitor pack WARNING! Follow the safety instructions, page 12. Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Remove the front cover, see (1) on page 99. Remove the profiled side plate. 2.

  • Page 104: Memory Unit

    104 Maintenance M6×12 combi screw M6×12 combi, 8 N·m (6 lbf·ft) M10, 30 N·m (22 lbf·ft) Capacitor pack removed Memory unit 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. The memory unit is located in the JCU Control Unit, see page 24.

  • Page 105: Technical Data

    The symbols are described below the table. Drive type Frame Input Output ratings size ratings Nominal IEC M2/M3 UL NEMA cont ACQ810-302A-4 ACQ810-361A-4 ACQ810-414A-4 ACQ810-477A-4 ACQ810-550A-4 ACQ810-616A-4 1017 ACQ810-704A-4 1017 00581898 Nominal input current (rms) Nominal output current. 110% overload is allowed for 1 minute every 5 minutes.

  • Page 106: Derating

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

  • Page 107: Fuses (Iec)

    = transformer impedance (%) = transformer rated voltage (V) = nominal apparent power of the transformer (kVA) = cable reactance (ohm). Calculation example Drive: • ACQ810-04-414A-4 • supply voltage U = 410 V Transformer: • rated power S = 3000 kVA •...
  • Page 108 + (4.438 mohm + 4.641 mohm) 2 · The calculated short-circuit current 9.7 kA is higher than the minimum short-circuit current of the drive gG fuse type OFAF3H500 (8280 A). -> The 500 V gG fuse (ABB Control OFAF3H500) can be used.

  • Page 109: Fuse Tables

    Technical data 109 Fuse tables gG fuses Drive type Input Min. Fuse ACq810-04… current short- circuit current Manufacturer Type size -302A-4 8280 2 900 000 500 ABB Control OFAF3H500 -361A-4 8280 2 900 000 500 ABB Control OFAF3H500 -414A-4 8280...

  • Page 110: Quick Guide For Selecting Between Gg And Ar Fuses

    Selection of smaller fuses improves the protection, but may also affect the fuse life time and lead to unnecessary operation of the fuses. In case of any uncertainty regarding the drive protection, please contact your local ABB representative. Fuses (UL) UL class T or L fuses for branch circuit protection per NEC are listed below.

  • Page 111: Ul Class T And L Fuses

    Technical data 111 UL class T and L fuses Drive type Input Fuse current ACS850-04… Manufacturer Type UL class -302A-4 Bussmann JJS-500 -361A-4 Bussmann JJS-500 -414A-4 Bussmann JJS-500 -477A-4 Bussmann JJS-600 -550A-4 Ferraz A4BY800 -616A-4 Ferraz A4BY800 -704A-4 Ferraz A4BY800 Note 1: See also Implementing thermal overload and short-circuit protection on page 62.

  • Page 112: Losses, Cooling Data And Noise

    112 Technical data Losses, cooling data and noise Drive type Frame Air flow Heat Noise size dissipation /min ACQ810-302A-4 1220 5000 ACQ810-361A-4 1220 6000 ACQ810-414A-4 1220 6850 ACQ810-477A-4 1220 7800 ACQ810-550A-4 1220 8100 ACQ810-616A-4 1220 9100 ACQ810-704A-4 1220 9700 00581898...

  • Page 113: Terminal And Lead-Through Data For The Power Cables

    Technical data 113 Terminal and lead-through data for the power cables Input, motor and DC cable terminal sizes (per phase), maximum accepted cable and tightening torques are given below. U1, V1, W1, U2, V2, W2, UDC+, UDC- Grounding PE Number of holes Max.

  • Page 114: Control Unit (Jcu-21) Connection Data

    114 Technical data Control unit (JCU-21) connection data Power supply 24 V (±10%) DC, 1.6 A Supplied from the power unit of the drive, or from an external power supply through connector XPOW (pitch 5 mm, wire size 2.5 mm Relay outputs RO1…RO2 Connector pitch 5 mm, wire size 2.5 mm (XRO1 …...
  • Page 115 Technical data 115 Analog outputs AO1 and Connector pitch 3.5 mm, wire size 1.5 mm 0…20 mA, R < 500 ohm load (XAO) Frequency range: 0…800 Hz Resolution: 11 bit + sign bit Inaccuracy: 2% of full scale range Drive to drive link Connector pitch 3.5 mm, wire size 1.5 mm (XD2D) Physical layer: RS-485...

  • Page 116: Efficiency

    116 Technical data Efficiency Approximately 98% at nominal power level Degree of protection IP00 (UL type open) 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...

  • Page 117: Materials

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

  • Page 118: Ce Marking

    118 Technical data CE marking A CE mark is attached to the drive module to verify that the unit follows the provisions of the European Low Voltage and EMC Directives. Compliance with the European Low Voltage Directive The compliance with the European Low Voltage Directive has been verified according to standards EN 61800- 5-1 and EN 60204-1.

  • Page 119: Category C3

    Equipment An EMC plan for preventing disturbances is drawn up for the installation. A template is available from the local ABB representative. The motor and control cables are selected as specified in the Hardware manual. The drive is installed according to the instructions given in the Hardware manual.

  • Page 120: Ul Marking

    Suitable IEC (class gG and aR) fuses are listed on page and UL (class T or L) fuses on page 110. For suitable circuit breakers, contact your local ABB representative. • For installation in the United States, branch circuit protection must be provided in accordance with the National Electrical Code (NEC) and any applicable local codes.

  • Page 121: Dimension Drawings

    Dimension drawings 121 Dimension drawings What this chapter contains This chapter contains dimension drawings of the drive modules as well as auxiliary components.

  • Page 122: Frame Without Pedestal (Mm)

    122 Dimension drawings Frame without pedestal (mm) Center of gravity 64801082_3/6 E...

  • Page 123: Frame With Busbars On The Left Side (Mm)

    Dimension drawings 123 Frame with busbars on the left side (mm)

  • Page 124: Drive Control Unit (Jcu)

    124 Dimension drawings Drive control unit (JCU)

  • Page 125: Package

    Dimension drawings 125 Package...

  • Page 126: Dimension Drawings (Usa)

    126 Dimension drawings Dimension drawings (USA) Frame without pedestal (inches) Center of gravity 68440513_3/6 A (64801082.asm E)

  • Page 127: Frame With Busbars On The Left Side (Inches)

    Dimension drawings 127 Frame with busbars on the left side (inches)
  • Page 128 128 Dimension drawings...

  • Page 129: Example Circuit Diagrams

    Example circuit diagrams 129 Example circuit diagrams What this chapter contains This chapter shows an example circuit diagram for a cabinet-installed drive module.

  • Page 130: Example Circuit Diagram

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

  • Page 131: Du/Dt Filters And Sine Filters

    When is du/dt filter needed? See section Checking the compatibility of the motor and drive, page 58. Selection table du/dt filter types for the drive module types are given below. Drive type du/dt filter type ACQ810-04-302A-4 FOCH-0320-50 ACQ810-04-361A-4 FOCH-0320-50 ACQ810-04-414A-4 FOCH-0320-50 ACQ810-04-477A-4 FOCH-0610-70...

  • Page 132: Sine Filters

    132 du/dt filters and sine filters Sine filters Contact your local ABB representative.

  • Page 133: 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 134 Contact us ABB Oy ABB Inc. ABB Beijing Drive Systems Co. Ltd. Drives Automation Technologies No. 1, Block D, A-10 Jiuxianqiao Beilu P.O. Box 184 Drives & Motors Chaoyang District FI-00381 HELSINKI 16250 West Glendale Drive Beijing, P.R. China, 100015...

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