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ABB ACQ800 Series Hardware Manual

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ACQ800
Hardware Manual
ACQ800-37 Drives (55 to 450 kW / 75 to 550 hp)

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Summary of Contents for ABB ACQ800 Series

  • Page 1 ACQ800 Hardware Manual ACQ800-37 Drives (55 to 450 kW / 75 to 550 hp)
  • Page 2 You can find manuals and other product documents in PDF format on the Internet. See section Document library on the Internet on the inside of the back cover. For manuals not available in the Document library, contact your local ABB representative.
  • Page 3 ACQ800-37 Drives 55 to 450 kW (75 to 550 hp) Hardware Manual 3AXD50000038534 REV A EN EFFECTIVE: 2016-06-01  2016 ABB Oy. All Rights Reserved.

  • Page 5: Safety Instructions

    ACQ800-37 Hardware Manual Safety instructions What this chapter contains This chapter contains safety instructions you must follow when installing, operating and servicing the drive. If ignored, physical injury or death may follow, or damage may occur to the drive, the motor or driven equipment. Read the safety instructions before you work on the unit.

  • Page 6: Installation And Maintenance Work

    ACQ800-37 Hardware Manual 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, or damage the equipment. WARNING! • Only qualified electricians are allowed to install and maintain the drive. •...
  • Page 7 ACQ800-37 Hardware Manual • The brake control terminals (UDC+, UDC-, R+ and R- terminals) carry a dangerous DC voltage (over 500 V). • Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V) may be present on the relay outputs of the drive system. Safety instructions...
  • Page 8 • Do not use the ramp which is supplied with the drive with heights over 50 mm (1.97 in) (the standard plinth height of ABB cabinets). The ramp is designed for a plinth height of 50 mm (1.97 in). Support the top and...

  • Page 9: Grounding

    ACQ800-37 Hardware Manual • When removing a module which is equipped with wheels, pull the module carefully out of the cubicle along the ramp. Make sure that the wires do not catch. While pulling on the handle, keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back.

  • Page 10: Fiber Optic Cables

    ACQ800-37 Hardware Manual • Do not install a drive equipped with an EMC (line) filter to an ungrounded power system or a high resistance-grounded (over 30 ohms) power system. Note: • Power cable shields are suitable for equipment grounding conductors only when adequately sized to meet safety regulations.

  • Page 11: Operation

    ACQ800-37 Hardware Manual 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. WARNING! • Before adjusting the drive and putting it into service, make sure that the motor and all driven equipment are suitable for operation throughout the speed range provided by the drive.
  • Page 12 ACQ800-37 Hardware Manual Safety instructions...

  • Page 13: Table Of Contents

    ACQ800-37 Hardware Manual Table of contents Safety instructions What this chapter contains ......... 5 Usage of warnings and notes .
  • Page 14 ACQ800-37 Hardware Manual Control panel ..........38 To control the supply unit…...
  • Page 15 ACQ800-37 Hardware Manual Equipment connected to the motor cable ......62 Installation of safety switches, contactors, connection boxes, etc..62 Bypass connection .
  • Page 16 ACQ800-37 Hardware Manual Installation of optional modules and PC ......76 Cabling of I/O and fieldbus modules .
  • Page 17 ACQ800-37 Hardware Manual Maintenance What this chapter contains ........93 Safety instructions .
  • Page 18 Product training ..........139 Providing feedback on ABB Drives manuals ......139 Document library on the Internet .

  • Page 19: About This Manual

    ACQ800-37 Hardware Manual About this manual What this chapter contains This chapter describes the intended audience and contents of the manual. It contains a flowchart of steps in checking the delivery, installing and commissioning the drive. The flowchart refers to chapters/sections in this manual and other manuals.

  • Page 20: Contents

    ACQ800-37 Hardware Manual Contents The chapters of this manual are briefly described below. Safety instructions gives safety instructions for the installation, commissioning, operation and maintenance of the drive. About this manual introduces this manual. The ACQ800-37 describes the drive. Mechanical installation instructs how to move, place and mount the drive.

  • Page 21: Installation And Commissioning Flowchart

    For instructions on how to disconnect the EMC/ If the drive is about to be connected to an IT RFI filtering, contact your local ABB (ungrounded) system: representative. • check that the drive is not equipped with EMC/RFI...

  • Page 22: Inquiries

    Address any inquiries about the product to the local ABB representative, quoting the type code and serial number of the unit. If the local ABB representative cannot be contacted, address inquiries to ABB Inc., Discrete Automation & Motion, Drives and Controls, 16250 West Glendale Drive, New Berlin, WI 53151.
  • Page 23 ACQ800-37 Hardware Manual Term/Abbreviation Explanation Motor-side converter A converter that is connected to the motor and controls the motor operation. With ACQ800-37 drives of frame size R8i, the motor-side converter is also called the inverter unit or INU. PPCS Power Plate Communication System; a protocol used in the optical fiber link that controls the output semiconductors of an inverter module.
  • Page 24 ACQ800-37 Hardware Manual About this manual...

  • Page 25: The Acq800-37

    ACQ800-37 Hardware Manual The ACQ800-37 What this chapter contains This chapter describes the construction of the drive in short. The ACQ800-37 The ACQ800-37 is a cabinet-built, low-harmonic drive for controlling AC motors. Cabinet line-up The drive consists of one or more cubicles that contain the supply and motor terminals, 1 IGBT supply module forming the line-side converter, 1 inverter module forming the motor-side converter, and optional equipment.

  • Page 26: Frame R6

    ACQ800-37 Hardware Manual Frame R6 The picture below shows the main components of a frame R6 drive with the door open, and with the swing-out frame closed (left) and open (right). Description Swing-out frame (see page 29) Cable entries for power and control cables (bottom cable entry/exit models) Cable entries for power and control cables (top cable entry/exit models)

  • Page 27: Frame R7I

    ACQ800-37 Hardware Manual Frame R7i The picture below shows the main components of a frame R7i drive with the door and the swing-out frame open. Description Swing-out frame (see page 29) (not shown). The drive control units for both converter modules are installed on the swing-out frame.

  • Page 28: Frame R8I

    ACQ800-37 Hardware Manual Frame R8i The picture below shows the main components of a frame R8i drive with the doors open. Description Swing-out frame (see picture on page 29) Supply unit controller (RDCU) Inverter unit controller (RDCU) Switch-disconnector Input contactor LCL filter IGBT supply module Intermediate DC link...

  • Page 29: Swing-Out Frame

    ACQ800-37 Hardware Manual Swing-out frame The swing-out frame provides space for the control circuitry of the drive as well as optional electrical equipment. The frame can be opened by removing the locking screws (arrowed in the picture below) and moving the swing-out frame aside. Depending on the frame size of the drive, the actual equipment of the drive may differ from what is depicted.
  • Page 30 ACQ800-37 Hardware Manual The following is a generic device layout diagram for the swing-out frame (drive frame size R8i). The diagram is also attached to the inside of the cubicle door, with installed devices marked. Refer to the circuit diagrams delivered with the drive for device designations.

  • Page 31: Cabling Direction

    ACQ800-37 Hardware Manual Cabling direction The drawings below show the available cabling directions of the drive. Frame size R6 Description Input/Motor output – Bottom entry IP21-42 IP54 Input/Motor output – Top entry (IP21-42) Input/Motor output – Top entry (IP54) Signal cable input/output – Bottom entry Signal cable input/output –...
  • Page 32 ACQ800-37 Hardware Manual Frame size R8i Description Input/output cubicle Supply and inverter unit cubicle Standard input (bottom entry) Standard input (top entry) Standard output (bottom exit) Standard output (top exit) Signal cable input/output – Bottom entry Signal cable input/output – Top entry (IP54) Signal cable input/output –...

  • Page 33: Operation Principle

    ACQ800-37 Hardware Manual Operation principle The line-side and motor-side converters have their own RDCU control units and control programs. The parameters of each program can be viewed and changed using one control panel. The converter to be controlled can be selected using the control panel;...
  • Page 34 ACQ800-37 Hardware Manual Typical line current (i ) and phase voltage (u ) waveforms are shown below. I , U t [ms] An example spectrum and THD value of the current at the input of the drive are shown below. Each harmonic is presented in percent of nominal current. n denotes the ordinal number of the harmonic.

  • Page 35: Motor-Side Converter

    ACQ800-37 Hardware Manual Motor-side converter 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 control is measured for earth fault (ground fault) protection. Frame R6 The motor-side converter is controlled by an RDCU drive control unit located in the integrated line-side/converter-side module.

  • Page 36: Controls

    ACQ800-37 Hardware Manual Controls Control interfaces of the drive The following diagram shows the control interfaces and I/O options of the drive. The ACQ800-37...

  • Page 37: Door Switches

    ACQ800-37 Hardware Manual Door switches Main switch-disconnector (Q1 in frame size R6 to R8i) The switch-disconnector handle switches the main and auxiliary voltages to the drive on and off. Other door switches These switches are only installed if the drive is equipped with the optional emergency stop function.

  • Page 38: Control Panel

    ACQ800-37 Hardware Manual Control panel A control panel (type CDP-312R) is installed on the door of the drive. The CDP-312R is the user interface of the supply unit (line-side converter) and the inverter unit (motor-side converter) of the drive, providing the essential controls such as Start/ Stop/Direction/Reset/Reference, and the parameter settings for the units’...

  • Page 39: Fieldbus Control Of The Line-Side Converter

    ACQ800-37 Hardware Manual Fieldbus control of the line-side converter Fieldbus control of the line-side converter is performed via the motor-side converter RMIO board as shown in the block diagram below. Block diagram: reference select The figure below shows the parameters for DC and reactive power reference selection in the ACQ800 Pump Control Program.

  • Page 40: Type Code

    ACQ800-37 Hardware Manual Type code The type code of the drive is indicated on the type designation label, attached on the cabinet door. The type code contains information on the specifications and configuration of the drive. The first digits from left express the basic configuration (e.g.

  • Page 41: Mechanical Installation

    ACQ800-37 Hardware Manual Mechanical installation What this chapter contains This chapter describes the mechanical installation procedure of the drive. General See chapter Technical data for allowable operating conditions and requirements for free space around the unit. The unit should be installed in an upright vertical position. The floor that the unit is installed on should be of non-flammable material, as smooth as possible, and strong enough to support the weight of the unit.

  • Page 42: Moving The Unit

    ACQ800-37 Hardware Manual Moving the unit …by crane Use the steel lifting lugs attached to the top of the cabinet. Insert the lifting ropes or slings into the holes of the lifting lugs. The lifting lugs can be removed (not mandatory) once the cabinet is in its final position.

  • Page 43: By Fork-Lift Or Pallet Truck

    ACQ800-37 Hardware Manual …by fork-lift or pallet truck The center of gravity may be quite high. So be careful when transporting the unit. Tilting the cabinets must be avoided. The units are to be moved only in the upright position. If using a pallet truck, check its load capacity before attempting to move the unit.

  • Page 44: Final Placement Of The Unit

    ACQ800-37 Hardware Manual Final placement of the unit The cabinet can be moved into its final position with an iron bar and a wooden piece at the bottom edge of the cabinet. Care is to be taken to properly place the wooden piece so as not to damage the cabinet frame.

  • Page 45: Before Installation

    ACQ800-37 Hardware Manual Before installation Delivery check The drive delivery contains: • drive cabinet line-up • optional modules (if ordered) installed into the control rack at the factory • ramp for extracting supply and inverter modules from the cabinet • hardware manual •...

  • Page 46: Installation Procedure

    ACQ800-37 Hardware Manual Installation procedure See detailed instructions in the following few pages. (1) The cabinet can be installed with its back against a wall, or back-to-back with another unit. Fasten the unit (or first shipping split) to the floor with fastening clamps or through the holes inside the cabinet.

  • Page 47: Fastening The Cabinet To The Floor

    ACQ800-37 Hardware Manual Fastening the cabinet to the floor The cabinet is to be fastened to the floor by using clamps along the edge of the cabinet bottom, or by bolting the cabinet to the floor through the holes inside. Clamping Insert the clamps into the twin slots along the front and rear edges of the cabinet frame body and fasten them to the floor with a bolt.

  • Page 48: Holes Inside The Cabinet

    ACQ800-37 Hardware Manual Holes inside the cabinet The cabinet can be fastened to the floor using the fastening holes inside the cabinet, if they are accessible. The recommended maximum distance between the fastening points is 800 mm (31.5 in). If there is not enough working space behind the cabinet for mounting, replace the lifting lugs at the top with L-brackets (not included) and fasten the top of the cabinet to the wall.

  • Page 49: Miscellaneous

    ACQ800-37 Hardware Manual Miscellaneous Cable conduit in the floor below the cabinet A cable conduit can be constructed below the 400 mm (15.75 in) wide middle part of the cabinet. The cabinet weight lies on the two 100 mm (3.94 in) wide transverse sections which the floor must carry.

  • Page 50: Cooling Air Intake Through Bottom Of Cabinet

    ACQ800-37 Hardware Manual Cooling air intake through bottom of cabinet Units with air intake through the bottom of the cabinet are intended for installation on an air duct in the floor. The required air inlets in the floor are as listed below. Refer also to the dimensional drawings delivered with the unit.

  • Page 51: Electric Welding

    ACQ800-37 Hardware Manual Electric welding It is not recommended to fasten the cabinet by welding. Cabinets without flat bars at the base • Connect the return conductor of the welding equipment to the cabinet frame at the bottom within 0.5 m (20 in) of the welding point. Cabinets with flat bars at the base •...
  • Page 52 ACQ800-37 Hardware Manual Mechanical installation...

  • Page 53: 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 54: 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 55 Motor type Nominal mains Requirement for voltage (AC line Motor insulation ABB du/dt filter, insulated N-end bearing and ABB common mode voltage) system filter < 100 kW 100 kW < P <...
  • Page 56 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 57 ACQ800-37 Hardware Manual Note 8: Calculating the rise time and the peak line-to-line voltage The peak line-to-line voltage at the motor terminals generated by the drive as well as the voltage rise time depend on the cable length. The requirements for the motor insulation system given in the table are “worst case”...

  • Page 58: Thermal Overload And Short-Circuit Protection

    ACQ800-37 Hardware Manual Thermal overload and short-circuit protection The drive protects itself and the input and motor cables against thermal overload when the cables are dimensioned according to the nominal current of the drive. No additional thermal protection devices are needed. 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.

  • Page 59: Selecting The Power Cables

    ACQ800-37 Hardware Manual Selecting the power cables General rules Dimension the supply (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. °...

  • Page 60: Alternative Power Cable Types

    ACQ800-37 Hardware Manual Alternative power cable types Power cable types that can be used with the drive are represented below. Recommended: Symmetrical shielded cable (three A separate PE conductor is required if the phase conductors, concentric or otherwise conductivity of the cable shield is less than 50% of the symmetrical PE conductor, overall shield) conductivity of a phase conductor.

  • Page 61: Motor Cable Shield

    ACQ800-37 Hardware Manual Motor cable shield To effectively suppress radiated and conducted radio-frequency emissions, the shield conductivity must be at least 1/10 of the phase conductor conductivity. The requirements are easily met with a copper or aluminium shield. The minimum requirement of the motor cable shield of the drive is shown below.

  • Page 62: Power Factor Compensation Capacitors

    ACQ800-37 Hardware Manual Power factor compensation capacitors Power factor compensation is not needed with AC drives. However, if a drive is to be connected in a system with compensation capacitors installed, note the following restrictions. WARNING! Do not connect power factor compensation capacitors to the motor cables (between the drive and the motor).

  • Page 63: Before Opening An Output Contactor (In Dtc Motor Control Mode)

    ACQ800-37 Hardware Manual Before opening an output contactor (in DTC motor control mode) Stop the drive and wait for the motor to stop before opening a contactor between the output of the drive and the motor when the DTC control mode is selected. (See the Firmware Manual of the drive for the required parameter settings.) Otherwise, the contactor will be damaged.

  • Page 64: Selecting The Control Cables

    Control panel cable In remote use, the cable connecting the control panel to the drive must not exceed 3 m (10 ft). The cable type tested and approved by ABB is used in control panel option kits. Coaxial cable (for use with Advant Controllers AC 80/AC 800) •...

  • Page 65: Connection Of A Motor Temperature Sensor To The Drive I/O

    ACQ800-37 Hardware Manual 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 66: Control Cable Ducts

    ACQ800-37 Hardware Manual A diagram of the cable routing is 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 230/120 V...

  • Page 67: Electrical Installation

    ACQ800-37 Hardware Manual Electrical installation What this chapter contains This chapter describes the electrical installation procedure of the drive. 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 injury or death.

  • Page 68: Before Installation

    Protective 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 69: Input Power Connection - Frame R6

    ACQ800-37 Hardware Manual Input power connection – Frame R6 Connection diagram Connection procedure Note: Before making the cable connections, check that the input of the auxiliary voltage transformer (T10) is selected correctly according to the supply voltage. 1. Open the door of the cabinet. 2.

  • Page 70: Input Power Connection - Frame R7I

    ACQ800-37 Hardware Manual Input power connection – Frame R7i Connection diagram Connection procedure Note: Before making the cable connections, check that the input of the auxiliary voltage transformer (T10) is selected correctly according to the supply voltage. 1. Open the door of the cabinet. 2.

  • Page 71: Input Power Connection - Frame R8I

    ACQ800-37 Hardware Manual Input power connection – Frame R8i Connection diagram Connection procedure Note: Before making the cable connections, check that the tap settings of the auxiliary voltage transformer (T10, located in the input/output cubicle) are correct in regard to the supply voltage. See instructions on page 77. 1.

  • Page 72: Grounding Of Shielded Single-Core Input Cables

    ACQ800-37 Hardware Manual Grounding of shielded single-core input cables Connect the cable shield to the PE busbar at the transformer side only and insulate the shield at the drive side. Motor connection – Frame R6 Connection diagram Connection procedure 1. Open the cabinet door. 2.

  • Page 73: Motor Connection - Frame R7I

    ACQ800-37 Hardware Manual Motor connection – Frame R7i Connection diagram Connection procedure 1. Open the cabinet door. 2. Remove any shrouds that protect the output busbars and cable entries. 3. Lead the cables into the inside of the cubicle. It is recommended to apply 360° grounding of the cable shields at the entry as shown below.

  • Page 74: Motor Connection - Frame R8I

    ACQ800-37 Hardware Manual Motor connection – Frame R8i Connection diagram Supply and inverter unit cubicle Input/output cubicle Connection procedure 1. Open the door of the input/output cubicle (see section Cabling direction starting on page 31). 2. Remove any shrouds that protect the output busbars and cable entries. 3.

  • Page 75: Control Connections

    ACQ800-37 Hardware Manual Control connections Drive control connections The control connections are made on the terminal blocks provided in the swing-out frame of the drive. Refer to the circuit diagrams delivered with the drive, and to chapter Motor control and I/O board (RMIO).

  • Page 76: Installation Of Optional Modules And Pc

    ACQ800-37 Hardware Manual Installation of optional modules and PC Optional modules (such as fieldbus adapters and I/O extension modules) are inserted into the optional module slot of the RMIO boards (built in the RDCU drive control units) and secured with two screws.

  • Page 77: Tap Settings Of The Auxiliary Voltage Transformer (Frame R8I)

    ACQ800-37 Hardware Manual Tap settings of the auxiliary voltage transformer (Frame R8i) 3~ Input Output 3~ input 1~ output 3~ output Tap settings 230 V 115 V 400 V (50 Hz) 320 V (60 Hz) Supply Supply Terminals voltage voltage A1 to...
  • Page 78 ACQ800-37 Hardware Manual Electrical installation...

  • Page 79: Motor Control And I/O Board (Rmio)

    ACQ800-37 Hardware Manual Motor control and I/O board (RMIO) What this chapter contains This chapter shows • external control connections to the RMIO board for the ACQ800 Pump Control Program • specifications of the inputs and outputs of the board. To which products this chapter applies This chapter applies to ACQ800 units which employ the RMIO-01 board (revision J or later) or the RMIO-02 board (revision H or later).

  • Page 80: External Control Connections (Us)

    ACQ800-37 Hardware Manual External control connections (US) External control cable connections to the RMIO board for the ACQ800 Pump Control Program (PFC TRAD) are shown below. For external control connections of other application macros and programs, see the appropriate Firmware Manual. Terminal block size: cables 0.3 to 3.3 mm (22 to 12 AWG)

  • Page 81: Rmio Board Specifications

    ACQ800-37 Hardware Manual RMIO board specifications Analog inputs With Pump Control Program two programmable differential current inputs (0 mA / 4 mA to 20 mA, R = 100 ohm) and one programmable differential voltage input (-10 V / 0 V / 2 V to +10 V, R >...

  • Page 82: Relay Outputs

    Maximum continuous current 2 A rms Isolation test voltage 4 kV AC, 1 minute DDCS fiber optic link With communication adapter module RDCO. Protocol: DDCS (ABB Distributed Drives Communication System) 24 V DC power input Voltage 24 V DC ± 10%...
  • Page 83 ACQ800-37 Hardware Manual 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 84 ACQ800-37 Hardware Manual Motor control and I/O board (RMIO)

  • Page 85: Installation Checklist And Start-Up

    ACQ800-37 Hardware Manual Installation checklist and start-up What this chapter contains This chapter contains an installation checklist, a start-up procedure for the drive, and listings of parameters specific to the ACQ800-37. Installation checklist Check the mechanical and electrical installation of the drive before start-up. Go through the checklist below together with another person.

  • Page 86: Start-Up Procedure

    ACQ800-37 Hardware Manual Start-up procedure Action Additional information WARNING! Ensure that the disconnector of the supply transformer is locked to open position, i.e. no voltage is, or cannot be connected to drive inadvertently. Check also by measuring that there is no voltage connected.

  • Page 87: Supply Unit (Line-Side Converter) Program Set-Up

    Note: The output voltage of the drive can be raised using a parameter setting; for example, it is possible to run a 500 V motor off a 400 V supply. Contact your local ABB representative for more information. Inverter control program set-up...

  • Page 88: Acq800-37-Specific Parameters In The Igbt Supply Control Program

    ACQ800-37 Hardware Manual ACQ800-37-specific parameters in the IGBT Supply Control Program The signals and parameters described in the tables below are included in the IGBT Supply Control Program. Terms and abbreviations Term Definition Boolean Character string Def. Default value FbEq Fieldbus equivalent: the scaling between the value shown on the control panel and the integer used in serial communication Integer...

  • Page 89: Default Values Of Parameters With The Acq800-37

    ACQ800-37 Hardware Manual Name/Value Description T./FbEq Def. 31.01 NUMBER OF TRIALS Defines the number of automatic fault resets the drive performs within the time defined by parameter 31.02. Note: When the value of parameter is not 0 and parameter 98.02 COMM.

  • Page 90: Acq800-37-Specific Parameters In The Inverter Control Program

    ACQ800-37 Hardware Manual ACQ800-37-specific parameters in the inverter control program The actual signals and parameters described in this section are included in the most commonly used inverter control program, ACQ800 Pump Control Program. Terms and abbreviations Term Definition Actual signal Signal measured or calculated by the drive.

  • Page 91: Actual Signals And Parameters Of The Supply Unit Control Program Visible Also In The Inverter Control Program

    ACQ800-37 Hardware Manual Actual signals and parameters of the supply unit control program visible also in the inverter control program Name/Value Description FbEq Def. 09 ACTUAL SIGNALS Signals from the supply unit (line-side converter). 09.12 LCU ACT SIGNAL 1 Line-side converter signal selected by par. 95.08 LCU PAR1 SEL. 1 = 1 09.13 LCU ACT SIGNAL 2...
  • Page 92 ACQ800-37 Hardware Manual Installation checklist and start-up...

  • Page 93: What This Chapter Contains

    • ensure there is no dangerous voltage present by measuring the voltage of the input terminals and the intermediate circuit terminals. 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 action Instruction...

  • Page 94: Checking And Replacing The Air Filters

    ACQ800-37 Hardware Manual Consult your local ABB Service representative for more details on the maintenance. On the Internet, go to http://www.abb.com/drivesservices. Checking and replacing the air filters 1. Read and repeat the steps in section Safety instructions on page 93.

  • Page 95: Quick Connectors (Frame R8I)

    ACQ800-37 Hardware Manual Quick connectors (Frame R8i) 1. Read and repeat the steps in section Safety instructions on page 93. 2. Open the cabinet doors. 3. Extract a supply module or inverter module from the cabinet. See section Power module replacement (Frame R8i) on page 104.

  • Page 96: Cooling Fans

    ACQ800-37 Hardware Manual Cooling fans Supply/Inverter module cooling fan replacement (Frame R6) 1. Read and repeat the steps in section Safety instructions on page 93. 2. Loosen the fastening screws of the fan housing. 3. Push the fan housing backwards. 4.

  • Page 97: Supply/Inverter Module Cooling Fan Replacement (Frame R7I)

    ACQ800-37 Hardware Manual Supply/Inverter module cooling fan replacement (Frame R7i) 1. Disconnect the wire plug. 2. Remove the two screws holding the fan unit. 3. Pull the fan unit slightly towards the front of the cubicle, then downwards to free it. 4.

  • Page 98: Lcl Filter Module Cooling Fan Replacement (Frame R7I)

    ACQ800-37 Hardware Manual LCL filter module cooling fan replacement (Frame R7i) 1. Disconnect the wire plug (1). 2. Remove the two screws holding the fan unit (2). 3. Pull the fan unit out (3). 4. Install the new fan in reverse order. Maintenance...

  • Page 99: Supply And Inverter Module Cooling Fan Replacement (Frame R8I)

    The actual lifespan of the fan depends on the running time of the fan, ambient temperature and dust concentration. Each supply and inverter module has its own cooling fan. Replacements are available from ABB. Do not use other than ABB specified spare parts.

  • Page 100: Lcl Filter Cooling Fan Replacement (Frame R8I)

    LCL filter cooling fan replacement (Frame R8i) The actual lifespan of the fan depends on the running time of the fan, ambient temperature and dust concentration. Replacements are available from ABB. Do not use other than ABB specified spare parts.

  • Page 101: Cabinet Fan Replacement (Frame R6)

    ACQ800-37 Hardware Manual Cabinet fan replacement (Frame R6) 1. Read and repeat the steps in section Safety instructions on page 93. 2. Open the cubicle door. 3. Remove the shroud covering the top of the cubicle. 4. Disconnect the fan wiring. Make note of the connections at the terminal block. 5.

  • Page 102: Cabinet Fan Replacement (Frame R8I With Ip54)

    ACQ800-37 Hardware Manual Cabinet fan replacement (Frame R8i with IP54) 1. Remove the front and back gratings of the fan cubicle by lifting them upwards. 2. Remove the shrouds by undoing the fastening screws. 3. Undo the fastening screws of the side/top cover of the fan. 4.

  • Page 103: Heatsinks

    Capacitor life can be prolonged by lowering the ambient temperature. It is not possible to predict 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.

  • Page 104: Power Module Replacement (Frame R8I)

    • Do not use the ramp which is supplied with the drive with heights over 50 mm (1.97 in) (the standard plinth height of ABB cabinets). The ramp is designed for a plinth height of 50 mm (1.97 in). Support the top and...

  • Page 105: Extracting The Module From The Cubicle

    WARNING! Do not use the ramp which is supplied with the drive with heights over 50 mm (1.97 in) (the standard plinth height of ABB cabinets). The ramp is designed for a plinth height of 50 mm (1.97 in).
  • Page 106 ACQ800-37 Hardware Manual Maintenance...
  • Page 107 ACQ800-37 Hardware Manual View from back: Maintenance...

  • Page 108: Inserting The Module Into The Cubicle

    ACQ800-37 Hardware Manual Inserting the module into the cubicle 1. Move the module close to the ramp, and then retract the support legs of the module. 2. Push the module up the ramp and back into the cubicle. WARNING! Keep your fingers away from the edge of the module front plate to avoid pinching them between the module and the cubicle.

  • Page 109: Fault Tracing

    ACQ800-37 Hardware Manual Fault tracing Faults and warnings displayed by the CDP-312R Control Panel The control panel will display the warnings and faults of the unit (i.e. supply unit or inverter unit) the panel is currently controlling. The warnings and faults concerning the inverter unit (motor-side converter) are dealt with in the inverter control program (e.g.

  • Page 110: Leds Of The Drive

    ACQ800-37 Hardware Manual LEDs of the drive Location Indication RMIO board (RDCU drive control Fault state. unit) Green The power supply on the board is OK. Control panel mounting platform Fault state. (with the control panel removed) Green The main + 24 V power supply for the control panel and the RMIO board is OK.

  • Page 111: Technical Data

    ACQ800-37 Hardware Manual Technical data What this chapter contains This chapter contains the technical specifications of the drive, e.g. ratings, frame sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings, and warranty information. IEC ratings The ratings for the ACQ800-37 with a 50 Hz supply are given below.

  • Page 112: Symbols

    At altitudes from 1000 to 4000 m (3281 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 113: Nema Ratings

    ACQ800-37 Hardware Manual NEMA ratings The ratings for the ACQ800-37 with a 60 Hz supply are given below. The symbols are described below the table. Heavy-duty Heat dis- Noise Nominal ratings Normal use Air flow sipation level ACQ800-37 type cont.max /min Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V or 480 V ACQ800-37-0070-5...

  • Page 114: Acq800-37 Frame Sizes And Power Module Types

    ACQ800-37 Hardware Manual ACQ800-37 frame sizes and power module types Supply module(s) used* LCL filter(s) used Inverter modules used* ACQ800-37 type Frame size Type Type Type Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V ACQ800-37-0070-5 ACS800-31-0070-5** ACQ800-37-0100-5...

  • Page 115: Input Power Connection

    ACQ800-37 Hardware Manual Input power connection Voltage (U 380/400/415/440/460/480/500 V AC 3-phase ± 10% for 500 V AC units Short-circuit withstand Units without grounding switch: Maximum allowable prospective short-circuit current is strength (IEC 60439-1) 65 kA when protected by the fuses given in the fuse tables. Units with grounding switch: Maximum allowable prospective short-circuit current is 50 kA when protected by the fuses given in the fuse tables.
  • Page 116 ACQ800-37 Hardware Manual Input terminals L1/L2/L3 – Bottom cable entry/exit Frame R6 Front view Bolt size: M10 Tightening torque: 40 Nm (29.5 lb-ft) 13 mm (0.51 in) 11 mm (0.43 in) 24 mm (0.94 in) Top cable entry/exit 24 mm (0.94 in) Front view Bolt size: M10 Tightening torque: 40 Nm (29.5 lb-ft)

  • Page 117: Motor Connection

    ACQ800-37 Hardware Manual Input terminals L1/L2/L3 – Front view 45 mm (1.77 in) Frame R8i Bolt size: M12 or 1/2 in Tightening torque: 70 Nm (52 lb-ft) 23 mm (0.90 in) 45 mm (1.75 in) 30 mm (1.18 in) Ø14 mm (Ø0.55 in) Motor connection Voltage (U 0 to U...
  • Page 118 ACQ800-37 Hardware Manual Output terminals U2/V2/W2 Bottom cable entry/exit – Frame R6 Front view Bolt size: M10 Tightening torque: 40 Nm (29.5 lb-ft) Ø11 mm (0.43 in) 13 mm (0.51 in) 24 mm (0.94 in) Top cable entry/exit 24 mm (0.94 in) Front view Bolt size: M10 Tightening torque: 40 Nm (29.5 lb-ft)

  • Page 119: Efficiency

    ACQ800-37 Hardware Manual Standard output terminals Bottom or top exit 45 mm (1.77 in) U2/V2/W2 – Frame R8i Front view Bolt size: M12 or 1/2 in Tightening torque: 70 Nm (52 lb-ft) 23 mm (0.90 in) 45 mm (1.75 in) Ø14 mm (0.55 in) 30 mm (1.18 in) Maximum recommended...

  • Page 120: Ambient Conditions

    ACQ800-37 Hardware Manual Ambient conditions Environmental limits for the drive are given below. The drive must 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 Supply voltage <...

  • Page 121: Tightening Torques For Power Connections

    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. Tightening torques for power connections Screw size Torque M5 3.5 Nm (2.6 lb-ft)

  • Page 122: Ce Marking

    ACQ800-37 Hardware Manual 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. The CE marking also verifies that the drive, in regard to its safety functions (such as Safe torque off), conforms with the Machinery Directive as a safety component.

  • Page 123: Declaration Of Conformity

    ACQ800-37 Hardware Manual Declaration of Conformity Technical data...
  • Page 124 ACQ800-37 Hardware Manual Technical data...

  • Page 125: Compliance With En 61800-3:2004

    ACQ800-37 Hardware Manual Compliance with EN 61800-3:2004 Definitions EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to operate without problems within an electromagnetic environment. Likewise, the equipment must not disturb or interfere with any other product or system within its locality. First environment includes establishments connected to a low-voltage network which supplies buildings used for domestic purposes.

  • Page 126: Category C4

    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 127: Dimensions

    (5.1 in) with top entry/exit models as well as units with cooling air intake through the bottom of the cabinet. • The measurements given apply to 6-pulse-input, non-UL/CSA units. For dimensions of 12-pulse-input or UL/CSA units, contact your local ABB representative. The tables are followed by example dimensional drawings.

  • Page 128: Frame R6

    ACQ800-37 Hardware Manual Frame R6 Dimensions...
  • Page 129 ACQ800-37 Hardware Manual [Frame R6 continued] Dimensions...

  • Page 130: Frame R7I

    ACQ800-37 Hardware Manual Frame R7i Dimensions...
  • Page 131 ACQ800-37 Hardware Manual [Frame R7i continued] Dimensions...
  • Page 132 ACQ800-37 Hardware Manual [Frame R7i continued] Dimensions...
  • Page 133 ACQ800-37 Hardware Manual [Frame R7i continued] Dimensions...

  • Page 134: Frame R8I

    ACQ800-37 Hardware Manual Frame R8i Dimensions...
  • Page 135 ACQ800-37 Hardware Manual [Frame R8i continued] Dimensions...
  • Page 136 ACQ800-37 Hardware Manual [Frame R8i continued] Dimensions...
  • Page 137 ACQ800-37 Hardware Manual [Frame R8i continued] Dimensions...
  • Page 138 ACQ800-37 Hardware Manual Dimensions...

  • Page 139: 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 140 ABB Inc. Discrete Automation & Motion Drives and Controls 16250 West Glendale Drive New Berlin, WI 53151 Telephone 800 752-0696 www.abb.com/drives...

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