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

Drive modules (160 to 560 kw, 200 to 700 hp)
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ABB machinery drives
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ACS850-04 drive modules (160 to 560 kW, 200 to 700 hp)

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  • Page 1 ABB machinery drives Hardware manual ACS850-04 drive modules (160 to 560 kW, 200 to 700 hp)

  • Page 2: List Of Related Manuals

    List of related manuals Drive hardware manuals and guides Code (English) ACS850-04 drive modules (160 to 560 kW, 200 to 700 hp) hardware manual 3AUA0000081249 Safe torque off function for ACSM1, ACS850 and ACQ810 drives application 3AFE68929814 guide Drive firmware manuals and guides...
  • Page 3 ACS850-04 drive modules 160 to 560 kW (200 to 700 hp) Hardware manual 3AUA0000081249 Rev C EFFECTIVE: 2013-04-11  2013 ABB Oy. All Rights Reserved.

  • Page 5: Table Of Contents

    Table of contents List of related manuals ............2 Table of contents Safety instructions What this chapter contains .
  • Page 6 Additional requirements for ABB high-output motors and IP23 motors ... . .53 Additional requirements for non-ABB high-output and IP23 motors ....54 Additional data for calculating the rise time and the peak line-to-line voltage .
  • Page 7 Relay cable type ............60 Control panel cable length and type .
  • Page 8 Mounting procedure ............90 Assembly drawing of installing the drive module to the cabinet (frame G1) .
  • Page 9 Cleaning the interior of the cabinet ......... . . 118 Heatsink .
  • Page 10 CSA marking ..............138 “C-tick”...
  • Page 11 Providing feedback on ABB Drives manuals ........

  • Page 12: Table Of Contents

    Table of contents...

  • Page 13: Safety Instructions

    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 14: Safety In Installation And Maintenance

    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: • Only qualified electricians are allowed to install and maintain the drive. •...

  • Page 15: Grounding

    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 16: Permanent Magnet Motor Drives

    Permanent magnet motor drives These are additional warnings concerning permanent magnet motor drives. WARNING! Ignoring the instructions can cause physical injury or death, or damage to the equipment. • Do not work on the drive when the permanent magnet motor is rotating. Also, when the supply power is switched off and the drive is stopped, a rotating permanent magnet motor feeds power to the intermediate circuit of the drive and the supply connections become live.

  • Page 17: General Safety

    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: • - Lift the drive module using the lifting lugs attached to the top and base of the unit.

  • Page 18: Fiber Optic Cables

    - Push the drive module into the cabinet and pull it from the cabinet carefully preferably with help from another person as shown below. Keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back.

  • Page 19: Printed Circuit Boards

    Printed circuit boards WARNING! Ignoring the following instructions can cause damage to the printed circuit boards: • Wear a grounding wrist band when handling the boards. Do not touch the boards unnecessarily. The printed circuit boards contain components sensitive to electrostatic discharge. Safe start-up and operation General safety These warnings are intended for all who plan the operation of the drive or operate...
  • Page 20 Safety instructions...

  • Page 21: Introduction To The Manual

    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 other manuals.

  • Page 22: Categorization By Frame Size And Option Code

    Start-up refers to the start-up instructions of the cabinet-installed drive. Fault tracing describes the LED indications and refers to the fault tracing instructions of the drive. Maintenance contains preventive maintenance instructions. Technical data contains the technical specifications of the drive module, eg, the ratings, sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings.
  • Page 23 Task Check the installation site. Fasten the base of the Checking the installation site (page 73) cabinet to floor. Ambient conditions (page 134) Planning the cabinet installation (page 37) Route the cables. Routing the cables (page 60) Check the insulation of the supply cable, the motor Checking the insulation of the assembly (page and the motor cable and the resistor cable (if present).

  • Page 24: Terms And Abbreviations

    Task Connect the external control cables to the drive control Connecting the control cables (page 95) unit. Control cable connection procedure of units with internal control unit (option +P905), page Check the installation. Installation checklist (page 109) Commission the drive. Start-up (page 113) Commission the brake chopper (if used).
  • Page 25 Frame (size) Size of the drive module. The drive modules described in this manual are of frame size G1 and G2. FSCA-01 Optional Modbus adapter High-threshold logic IGBT Insulated gate bipolar transistor; a voltage-controlled semiconductor type widely used in converters due to their easy controllability and high switching frequency.
  • Page 26 Introduction to the manual...

  • Page 27: Operation Principle And Hardware Description

    This chapter describes the operating principle and construction of the drive module in short. Product overview The ACS850-04 is a drive module for controlling asynchronous AC induction motors, permanent magnet motors and ABB synchronous reluctance motors (SynRM motors). The main circuit of the drive module is shown below.

  • Page 28: Layout

    Layout The components of the standard unit are shown below. W1, V1, U1 W2, V2, U2 Item Description Drive module Lifting lugs Fastening bracket Input cable connection busbars and optional DC+ and DC- busbars (+H356) Circuit board compartment Power supply and fiber optic cables to be connected to the external control unit Output cable connection busbars and optional brake resistor connection busbars (+D150) PE terminal Control cable duct...
  • Page 29 Item Description Base fastening screws Handle for pulling the drive module out of the cabinet Pedestal guide plate Telescopic extraction and insertion ramp Top guide plate Optional common mode filter (+E208) Grounding busbar Control unit (JCU) Control unit with front cover Control unit with front cover removed Control cable clamp plate Operation principle and hardware description...
  • Page 30 The drive module and optional selections are shown below: control unit and control panel variations and cabling panels. Item Description Drive module Input power cabling panel to be fastened to the cabinet (+H381 or +H383) Output power cabling panel to be fastened to the cabinet (+H381 or +H383) Front cover.
  • Page 31 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 Digital input/outputs Slots 1 and 2 for optional I/O extension Analog inputs and encoder/resolver interface modules Analog outputs Drive-to-drive link...

  • Page 32: Power Connections And Control Interfaces

    Power connections and control interfaces The diagram shows the power connections and control interfaces of the drive module. XPOW XRO1…3 XD24 Slot 1 XDIO XD2D XSTO Slot 2 Slot 3 t° UDC+ UDC- Slot 1 and I/O extension modules (FIO-01, FIO-11, FIO-21) 1) For information on the default Slot 2 and/or encoder or resolver interface modules...

  • Page 33: External Control Unit Connection Cables

    The cables for connecting the drive module and control panel to the control unit are shown below. See sections Connecting the external control unit to the drive module (page 97) and Connecting a PC (page 108) for the actual connections. ACS850-04 JRIB APOW 2560 mm (8.4 ft) JINT JGDR 3 m (9.8 ft)

  • Page 34: Type Designation Label

    Type designation label The type designation label includes an IEC and NEMA rating, CE and cULus, and CSA markings, a type designation and a serial number, which allow individual recognition of each unit. The type designation label is located on the front cover. An example label is shown below.

  • Page 35: Type Designation Key

    The first digits from left express the basic configuration. The optional selections are given thereafter, separated by plus signs, eg, +E208. The main selections are described below. Not all selections are available for all types. For more information, refer to ACS850-04 Ordering Information (3AXD00000579470), available on request. Code...
  • Page 36 Code Description Fieldbus adapter modules K451 FDNA-01 DeviceNet™ fieldbus adapter module ® K452 FLON-01 LonWorks fieldbus adapter module K454 FPBA-01 PROFIBUS DP fieldbus adapter module K457 FCAN-01 CANopen fieldbus adapter module K458 FSCA-01 Modbus fieldbus adapter module ® K469 FECA-01 EtherCAT fieldbus adapter module K473 FENA-11 Ethernet/IP™, Modbus/TCP and PROFINET IO fieldbus adapter module...

  • Page 37: Planning The Cabinet Installation

    Limitation of liability 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. Basic requirements for the cabinet Use a cabinet which: •...

  • Page 38: Layout Examples, Door Closed

    Layout examples, door closed This diagram shows a cabinet layout example with the input power cable lead- through from top and the motor cable lead-through from bottom. Air inlet for the drive module Air inlet for the other equipment. An extra fan is not necessary if an extra air baffle is used on the cabinet roof (see next page).
  • Page 39 Supporting frame of the cabinet JCU control unit. Vertical (2a, 2b) and horizontal (2c, 2d) air Note: With an internal control unit (option +P905), the baffles that separate the cool and hot air inlet 17 is critical for proper cooling of the control areas (leak-proof lead-throughs).

  • Page 40: Arranging The Grounding Inside The Cabinet

    • Always fasten the drive module from its fastening points to the cabinet. For details, see the module installation instructions. WARNING! Do not fasten the cabinet by electric welding. ABB does not assume any liability for damages caused by electric welding as the welding circuit may damage electronic circuits in the cabinet.

  • Page 41: Planning The Cabinet Placement On A Cable Channel

    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 will lie on the sections that the floor carries.
  • Page 42 • 360° high frequency grounding of the cable shields at the cable lead-throughs improves the EMC shielding of the cabinet. • 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.

  • Page 43: Planning The Grounding Of The Cable Shields At The Cabinet Lead-Through

    Planning the grounding of the cable shields at the cabinet lead-through Follow the principle shown below when planning the grounding of the cable shields at the cabinet lead-through. To power cable terminals Cable shield PE (ground) terminal of the cabinet, cabling panel or drive module Stripped part of the cable EMC sleeve...
  • Page 44 • Leave enough free space around 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 47. • Also ventilate the heat dissipated by cables and other additional equipment. •...

  • Page 45: Preventing The Recirculation Of Hot Air

    Preventing the recirculation of hot air Prevent hot air circulation outside the cabinet by leading the outcoming hot air away from the area where the inlet air to the cabinet is taken. Possible solutions are listed below: • gratings that guide air flow at the air inlet and outlet •...
  • Page 46 C – C A - A B - B Planning the cabinet installation...

  • Page 47: Required Free Space

    The module is designed to be installed in a cabinet with the following measurements: width 400 mm (15.75 in.), depth 600 mm (23.62 in.) and height 2000 mm (78.74 in.). Other installation positions Contact your local ABB representative. Planning the cabinet installation...

  • Page 48: Planning The Placement Of The Control Panel

    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 of the drive. See page 30. • The control panel can be mounted onto the cabinet door using the control panel mounting kit (+J410).

  • Page 49: 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 50: Protecting The Motor Insulation And Bearings

    Checking the compatibility of the motor and drive Use an asynchronous AC induction motor, a permanent magnet motor or an ABB synchronous reluctance motor (SynRM) with the drive. Several induction motors can be connected at a time but only one permanent magnet motor.

  • Page 51: Requirements Table

    Requirements table The following table shows how to select the motor insulation system and when optional ABB du/dt filters, insulated N-end (non-drive end) motor bearings and ABB common mode filters are required. Failure of the motor to fulfil the following requirements or improper installation may shorten motor life or damage the motor bearings and voids the warranty.
  • Page 52 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 < 350 kW > 350 kW frame size > IEC 315 frame size <...

  • Page 53: Additional Requirements For Explosion-Safe (Ex) Motors

    All HXR machines manufactured in Helsinki starting 1.1.1998 have form- wound windings. Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and Use the selection criteria given for non-ABB motors. Additional requirements for the braking applications...

  • Page 54: Additional Requirements For Non-Abb High-Output And Ip23 Motors

    The rated output power of high output motors is higher than what is stated for the particular frame size in EN 50347:2001. The table below shows the requirements for random-wound and form-wound non-ABB motors with nominal power smaller than 350 kW. For bigger motors, consult the motor manufacturer.

  • Page 55: Additional Data For Calculating The Rise Time And The Peak Line-To-Line Voltage

    Additional data for 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 56: Selecting The Power Cables

    Selecting the power cables General rules Dimension the input power and motor cables according to local regulations: • Dimension the cable to carry the drive load current. See chapter Technical data for the rated currents. ° ° • Select a cable rated for at least 70 C (158 F) maximum permissible temperature of conductor in continuous use.

  • Page 57: Typical Power Cable Sizes

    The table below gives copper and aluminium cable types with concentric copper shield for the drives with nominal current. See also Terminal and lead-through data for the power cables on page 129. Drive type ACS850-04 Cu cable type Al cable type Cu cable type Al cable type AWG/kcmil AWG/kcmil -387A-5 2 ×...

  • Page 58: Alternative Power Cable Types

    Alternative power cable types The power cable types that can be used with the drive are represented below. Recommended: Symmetrical shielded cable: three phase conductors and a concentric or otherwise symmetrically constructed PE conductor, and a shield PE conductor Shield and shield Shield Note: A separate PE conductor is...

  • Page 59: Additional Us Requirements

    Copper wire screen Helix of copper tape Inner insulation Insulation jacket or copper wire Cable core Additional US requirements Use type MC continuous corrugated aluminum armor cable with symmetrical grounds or shielded power cable for the motor cables if metallic conduit is not used. For the North American market, 600 V AC cable is accepted for up to 500 V AC.

  • Page 60: Signals In Separate Cables

    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

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

  • Page 62: Continuous Motor Cable Shield Or Enclosure For Equipment In The Motor Cable

    Protecting the drive and input power cable in short-circuits Protect the drive with fuses (1) and the input cable with fuses (2) as shown below: ACS850-04 Size the fuses at the distribution board according to local regulations for the input cable protection.

  • Page 63: Protecting The Drive And The Input Power And Motor Cables Against Thermal Overload

    Protecting the drive and the input power and motor cables against thermal overload 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.

  • Page 64: Implementing The Emergency Stop Function

    Implementing the Emergency stop function For safety reasons, install the emergency stop devices at each operator control station and at other operating stations where emergency stop may be needed. Note: Pressing the stop key ( ) on the control panel of the drive does not generate an emergency stop of the motor or separate the drive from dangerous potential.

  • Page 65: Implementing A Safety Switch Between The Drive And Motor

    If there are power factor compensation capacitors in parallel with the three phase input of the drive: 1. Do not connect a high-power capacitor to the power line while the drive is connected. The connection will cause voltage transients that may trip or even damage the drive.

  • Page 66: Implementing A Bypass Connection

    Implementing a bypass connection If bypassing is required, employ mechanically or electrically interlocked contactors between the motor and the drive and between the motor and the power line. Ensure with interlocking that the contactors cannot be closed simultaneously. WARNING! Never connect the supply power to the drive output terminals U2, V2 and W2.

  • Page 67: Switching The Motor Power Supply From Drive To Direct-On-Line

    Switching the motor power supply from drive to direct-on-line 1. Stop the drive and the motor with the drive control panel (drive in the local control mode) or the external stop signal (drive in the remote control mode). 2. Open the main contactor of the drive with S11. 3.

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

    230 V AC 230 V AC 24 V DC 1) Relay outputs; 2) Varistor; 3) RC filter; 4) Diode Connecting 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.

  • Page 69: Installation

    Rittal support rails) Always follow the general rules given in this chapter and local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches local laws and/or other regulations. Note 1: The drive module can also be installed in other than Rittal TS 8 cabinets.
  • Page 70 Note 2: Installations with input and motor cables of size 4 × 240 mm phase If resistor cables are to be connected, the lower side plate of the output cabling panel must be removed and the resistor cables lead from side to the terminals of the output cabling panel.
  • Page 71 Note 4: Mounting the drive module to an assembly panel Mount the assembly support as shown below. M4×12 Torx Installation...
  • Page 72 Note 5: Mounting the rubber grommet of units with optional cabling panels (+H381) Installing the input power cables through the rubber grommet of the optional cabling panels provides the degree of protection of IP20 for the unit. Mount the grommet as follows: 1.

  • Page 73: Safety

    Note 6: Alternative installation means In addition to the installation examples presented in this chapter, there are a few alternative installation means, such as: • The power cables can be connected directly to the drive module input and output terminals with cable lugs or by busbars. The drive module can also be installed self standing to the floor in an electrical equipment room when the power cable terminals and electrical parts are protected against contact and the unit is grounded properly.

  • Page 74: Moving And Unpacking The Unit

    Moving and unpacking the unit WARNING! Follow the safety instructions, page 14. Ignoring the instructions can cause physical injury or death, or damage to the equipment Move the transport package by pallet truck to the installation site. Unpack the package as follows: •...
  • Page 75 Ramp package contents Screw package PE terminal Cardboard box Feed through Pedestal guide plate Telescopic extraction and insertion ramp Fastening bracket Top guide plate Support Output power cabling panel (option +H381 or +H383) package contents Paper fill Cardboard tray Top cardboard cover Support Bands Plastic bag...

  • Page 76: Checking The Delivery

    Input power cabling panel (option +H381 or +H383) package contents Screw package Paper fill Input power cabling panel Cardboard tray Top cardboard cover Support Bands Plastic bag Rubber grommet (+H381 only) Grounding busbar to be connected to the input power cabling panel and the drive module *) *) If you cannot find the busbar in this package, it can be found in the output cabling panel package.

  • Page 77: Motor And Motor Cable

    2. Measure the insulation resistance between each phase conductor and the Protective Earth conductor using a measuring voltage of 1000 V DC. The insulation resistance of an ABB motor must exceed 100 Mohm (reference value at 25 °C or 77 °F). For the insulation resistance of other motors, please consult the manufacturer’s instructions.

  • Page 78: Overall Flowchart Of The Installation Process

    Overall flowchart of the installation process This flowchart describes the installation process of the units listed under What this chapter contains on page 69. Step Task For instructions, see Install the Rittal parts, cabinet bottom plate, drive Installing the mechanical accessories bottom guide plate and top guide and loose drive into the cabinet, page...

  • Page 79: Installing The Mechanical Accessories Into The Cabinet

    Installing the mechanical accessories into the cabinet For frame G1, see the assembly drawing on page 81. For frame G2, see the assembly drawing on page 82. Install the mechanical accessories into the cabinet as follows: 1. If you use a bottom plate, make the bottom plate according to the dimension drawing on page 150) and install the bottom plate on the bottom of the cabinet.
  • Page 80 9. Mount the grounding busbar to the input cabling panel (option +H381 or +H383). Back view is shown below. M8×16 Torx M8×16 Torx Frame size G2 Frame size G1 10.Mount the side guides to the input cabling panel (2 screws for each side guide) and mount the input cabling panel to the punched section.

  • Page 81: Assembly Drawing (Frame G1)

    Assembly drawing (frame G1) Installation...

  • Page 82: Assembly Drawing (Frame G2)

    Assembly drawing (frame G2) Installation...

  • Page 83: Assembly Drawing (Air Baffles)

    Assembly drawing (air baffles) Installation...

  • Page 84: Connecting The Power Cables

    Connecting the power cables WARNING! Follow the safety instructions, page 14. Ignoring the instructions can cause physical injury or death, or damage to the equipment Connection diagram (PE) (PE) ACS850-04 UDC+ UDC+ INPUT OUTPUT V2 W2 Motor Installation...
  • Page 85 For alternatives, see section Selecting the supply disconnecting device on page In the mounting example of this chapter, the disconnecting device is not in the same cubicle with the drive module. If a shielded cable is used (not required but recommended) and the conductivity of the shield is <...

  • Page 86: Power Cable Connection Procedure

    Power cable connection procedure WARNING! Follow the instructions in chapter Safety instructions. Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Lead the input cables into the inside of the cabinet. Ground the cable shield 360° at the lead-through plate.
  • Page 87 Note: The input and output power cables must fit inside the area marked with diagonal lines in the image below to avoid chafing of the cables when the drive module is inserted into the cabinet. U1, V1, W1 102 mm (4 in.) U2, V2, W2 View without cabinet side plate in place.

  • Page 88: 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 utilised by the other drives in the motoring mode. For more information, see Common DC configuration application guide for ACS850-04 drive modules (3AUA0000073108 [English]). Installation...

  • Page 89: Mounting The Drive Module Into The Cabinet

    Mounting the drive module into the cabinet WARNING! Follow the safety instructions, page 14. Ignoring the instructions can cause physical injury or death, or damage to the equipment. Handle the drive module carefully. Make sure that the module does not fall down when moving it on the floor and during installation and maintenance work: Open the support legs by pressing each leg a little down and turning it aside (1, 2).

  • Page 90: Mounting Procedure

    Mounting procedure 1. Mount the fastening bracket to the drive module. M8×20 Hex 2. Mount the grounding busbar that has been previously mounted to the input cabling panel to the drive module. Note: The design of the grounding busbar can differ from what is shown in the figure.
  • Page 91 3. Install the extraction and insertion ramp to the cabinet base with two screws. 4. Remove the upper and lower left-side front covers of the drive module. M4×8 combi screws, 2 N· m. 5. Push the drive module carefully into to the cabinet preferably with help from another person.
  • Page 92 Installation...

  • Page 93: Assembly Drawing Of Installing The Drive Module To The Cabinet (Frame G1)

    Assembly drawing of installing the drive module to the cabinet (frame G1) Installation...

  • Page 94: Assembly Drawing Of Installing The Drive Module To The Cabinet (Frame G2)

    Assembly drawing of installing the drive module to the cabinet (frame G2) Installation...

  • Page 95: Removing The Protective Covering From The Module Air Outlet

    Removing the protective covering from the module air outlet WARNING! Remove the protective covering from the top of the drive module after the installation. If the covering is not removed, the cooling air cannot flow freely through the module and the drive will run to overtemperature. Connecting the control cables Flowchart of the control cable installation process (external control unit) Step...

  • Page 96: Removing The Cover Assembly Of The External Control Unit

    Removing the cover assembly of the external control unit 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. 1.

  • Page 97: Fastening The Control Cable Clamp Plate

    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) Connecting the external control unit to the drive module WARNING! Handle the fiber optic cables with care.
  • Page 98 JRIB JRIB APOW RXD = receiver TXD = transmitter 3AUA0000038989 Installation...

  • Page 99: Mounting The External Control Unit

    Mounting the external 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. Mounting the external control unit to wall 1. Fasten the fastening screws in the wall. 2.

  • Page 100: Mounting The External Control Unit Vertically On A Din Rail

    Mounting the external control unit vertically on a DIN rail 1. Fasten the latch (A) to the back of the control unit with three screws. 2. Click the control unit to the rail as shown below (B). 3aua0000038989 Mounting the control unit horizontally on a DIN rail 1.

  • Page 101: Installing Optional Modules

    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. See page for the available slots. 1. Remove the control unit cover. 2.

  • Page 102: Connecting The Control Cables To The Terminals Of The Control Unit

    Connecting the control cables to the terminals of the control unit 1. Route the cables to the control unit as shown below. 1.5 N·m (13 lbf·in) 2. Ground the shields of the control cables at the clamp plate. The shields should be continuous as close to the terminals of the control unit as possible.
  • Page 103 The shield can also be grounded directly at both ends if they are in the same ground line with no significant voltage drop between the end points.Tighten the screws to secure the connection. 3. Connect the conductors to the appropriate detachable terminals of the control unit.

  • Page 104: Default I/O Connection Diagram

    Default I/O connection diagram XPOW Notes: +24VI External power input […] denotes default setting with ACS850 24 V DC, 1.6 A Standard Control Program (Factory macro). See the firmware manual for other XRO1, XRO2, XRO3 macros. Relay output RO1 [Ready] *Total maximum current: 200 mA 250 V AC / 30 V DC The wiring shown is for demonstrative...

  • Page 105: Jumpers

    Jumpers DI/DIO grounding selector (located between XD24 and XDI) – Determines whether the DIGND (ground for digital inputs DI1…DI5) floats, or if it is connected to DIOGND (ground for DI6, DIO1 and DIO2). See the JCU isolation and grounding diagram on page 133.

  • Page 106: External Power Supply For The Jcu Control Unit (Xpow)

    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 107: Drive-To-Drive Link (Xd2D)

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

  • Page 108: Safe Torque Off (Xsto)

    Note: Keep any signal wire pairs twisted as close to the terminals as possible. Twisting the wire with its return wire reduces disturbances caused by inductive coupling. Connecting a PC Connect the PC to the drive control unit as follows:. ACS850-04 Installation...

  • Page 109: Installation Checklist

    Installation checklist What this chapter contains This chapter contains a list for checking the mechanical and electrical installation of the drive. Installation checklist Go through the checklist below together with another person. WARNING! Follow the safety instructions, page 14. Ignoring the instructions can cause physical injury or death, or damage to the equipment Check that …...
  • Page 110 Check that … Connection of cables to devices, terminal blocks and drive module circuit boards: • Cables are connected to terminals tight enough by pulling the cable. • Cable termination on terminals chaining is done correctly. • Bare conductors are not too far outside the terminal causing an insufficient clearance or loss of shielding against contact.
  • Page 111 Check that … The supply voltage matches the nominal input voltage of the drive. Check the type designation label. The input power cable has been connected to the appropriate terminals, the phase order is right, and the terminals have been tightened. (Pull the conductors to check.) Appropriate AC fuses and main disconnector have been installed.
  • Page 112 Installation checklist...

  • Page 113: Start-Up

    Start-up What this chapter contains This chapter refers to the start-up instructions of the drive. Start-up procedure 1. Ensure that the installation of the drive has been checked according to the checklist in chapter Installation checklist, and that the motor and driven equipment are ready for start.
  • Page 114 Start-up...

  • Page 115: Fault Tracing

    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 116 Fault tracing...

  • Page 117: Maintenance

    Installation. The other maintenance instructions are general. 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 Check the main cooling fan Maintenance if needed.

  • Page 118: Cabinet

    Note: Perform the maintenance tasks of the cabinet (for example, clean the air inlet and outlet filters) when necessary and according to the cabinet manufacturer’s instructions. Consult your local ABB Service representative for more details on the maintenance. On the Internet, go to http://www.abb.com/drivesservices. Cabinet Cleaning the interior of the cabinet WARNING! Follow the safety instructions, page 14.

  • Page 119: Heatsink

    Heatsink The module heatsink fins pick up dust from the cooling air. The drive runs into overtemperature warnings and faults if the heatsink is not clean. Cleaning the interior of the heatsink WARNING! Follow the safety instructions, page 14. Ignoring the instructions can cause physical injury or death, or damage to the equipment.

  • Page 120: Fans

    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. Replacing the circuit board compartment cooling fan WARNING! Follow the safety instructions, page 14.

  • Page 121: Replacing The Main Cooling Fans

    Replacing the main cooling fans WARNING! Follow the safety instructions, page 14. Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Remove the drive module out of the cabinet as described in section Replacing the drive module on page 122.

  • Page 122: Replacing The Drive Module

    Replacing the drive module WARNING! Follow the safety instructions, page 14. Ignoring the instructions can cause physical injury or death, or damage to the equipment. Handle the drive module carefully. Make sure that the module does not fall down when moving it on the floor and during installation and maintenance work: Open the support legs by pressing each leg a little down and turning it aside (1, 2).
  • Page 123 9. Pull the drive module carefully out of the cabinet preferably with help from another person. 10.Install the new module in reverse order to the above. Maintenance...

  • Page 124: Capacitors

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

  • Page 125: Technical Data

    The ratings of the drive modules with 400 V, 460 V and 500 V (50 Hz and 60 Hz) supply are given below. Drive type Frame Input Output ratings size rating Nominal use Light-overload use Heavy-duty use ACS850-04 = 400 V -387A-5 -500A-5 -580A-5 -650A-5 -710A-5 -807A-5 1020 -875A-5 1100...

  • Page 126: Derating

    The power ratings apply to most IEC 34 motors at the nominal voltage of 400 V or 500 V. The DriveSize dimensioning tool available from ABB is recommended for selecting the drive, motor and gear combination for the required motion profile.

  • Page 127: Fuses (Iec)

    Fuses (IEC) Ultrarapid (aR) fuses Drive type Input Fuse ACS850-04 current Manufacturer Type DIN 43620 Size -387A-5 220000 Bussmann 170M6810D DIN3 -500A-5 490000 Bussmann 170M6812D DIN3 -580A-5 1000 985000 Bussmann 170M6814D DIN3 -650A-5 1000 985000 Bussmann 170M6814D DIN3 -710A-5 1250...

  • Page 128: Dimensions, Weights And Free Space Requirements

    Dimensions, weights and free space requirements Drive type Frame Weight 1 ACS850-04 size -387A-5 1462 1590 -500A-5 1462 1590 -580A-5 1462 1590 -650A-5 1462 1590 -710A-5 1662 1740 -807A-5 1662 1740 -875A-5 1662 1740 Drive type Frame Weight 1 ACS850-04...

  • Page 129: Losses, Cooling Data And Noise

    Losses, cooling data and noise Drive type Frame Air flow Heat dissipation Noise size /min dB(A) ACS850-04 -387A-5 1200 4403 -500A-5 1200 5602 -580A-5 1200 6409 -650A-5 1200 8122 -710A-5 1200 8764 -807A-5 1200 9862 -875A-5 1420 10578 Terminal and lead-through data for the power cables The maximum accepted cable size is 4 ×...

  • Page 130: Units Without Optional Cabling Panels (No +H381 Or +H383)

    Fundamental power factor 0.98 (at nominal load) (cos phi Motor connection data Motor types asynchronous AC induction motors, permanent magnet motors, ABB synchronous reluctance motors (SynRM motors) Voltage (U 0 to U , 3-phase symmetrical, U at the field weakening point Frequency DTC mode: 0 to 3.2 ·...

  • Page 131: Dc Connection Data

    DC connection data Drive module type Capacitance (mF) ACS850-04-387A-5 ACS850-04-500A-5 ACS850-04-580A-5 ACS850-04-650A-5 ACS850-04-710A-5 ACS850-04-807A-5 1033 ACS850-04-875A-5 1120 Control unit (JCU-11) 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...
  • Page 132 Analog inputs AI1 and AI2 Connector pitch 3.5 mm, wire size 1.5 mm (XAI:4 … XAI:7). Current input: –20…20 mA, R 100 ohm Voltage input: –10…10 V, R : 200 kohm Current/voltage input mode Differential inputs, common mode ±20 V selection by jumpers.

  • Page 133: Efficiency

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

  • Page 134: Ambient Conditions

    Ambient conditions Environmental limits for the drive are given below. The drive is to be used in a heated, indoor, controlled environment. Operation Storage Transportation installed for stationary use in the protective package in the protective package Installation site altitude Non-corner grounded TN and TT systems: 0 to 4000 m (13123 ft) above sea level.

  • Page 135: Materials

    IEC 62635 guidelines. To aid recycling, plastic parts are marked with an appropriate identification code. Please contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recyclers. End of life treatment must follow international and local regulations.

  • Page 136: 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. 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 137: Category C3

    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 138: Ul Marking

    • The input cable must be protected with fuses. Circuit breakers must not be used without fuses in the USA. For suitable circuit breakers, contact your local ABB representative. Suitable IEC (class aR) fuses and UL (class J) fuses for drive protection are listed on page 127.

  • Page 139: Disclaimer

    Disclaimer The manufacturer shall have no obligation with respect to any product which (i) has been improperly repaired or altered; (ii) has been subjected to misuse, negligence or accident; (iii) has been used in a manner contrary to the manufacturer's instructions; or (iv) has failed as a result of ordinary wear and tear.
  • Page 140 Technical data...

  • Page 141: Dimension Drawings

    Dimension drawings What this chapter contains This chapter contains dimension drawings of the drive modules with optional parts for Rittal TS 8 cabinet assembly. Dimension drawings...

  • Page 142: Frame G1 - Drive Module Dimensions

    Frame G1 – Drive module dimensions Dimension drawings...

  • Page 143: Frame G1 - Drive Module Dimensions With Optional Cabling Panels (+H381)

    Frame G1 – Drive module dimensions with optional cabling panels (+H381) Dimension drawings...
  • Page 144 Dimension drawings...

  • Page 145: Frame G1 - Cabling Panels (+H383) Installed Into A Rittal Ts 8 Cabinet

    Frame G1 – Cabling panels (+H383) installed into a Rittal TS 8 cabinet Dimension drawings...

  • Page 146: Frame G2 - Drive Module Dimensions

    Frame G2 – Drive module dimensions Dimension drawings...

  • Page 147: Frame G2 - Drive Module Dimensions With Optional Cabling Panels (+H381)

    Frame G2 – Drive module dimensions with optional cabling panels (+H381) Dimension drawings...
  • Page 148 Dimension drawings...

  • Page 149: Frame G2 - Cabling Panels (+H383) Installed Into A Rittal Ts 8 Cabinet

    Frame G2 – Cabling panels (+H383) installed into a Rittal TS 8 cabinet Dimension drawings...

  • Page 150: Frames G1 And G2 - Bottom Plate

    – Frames G1 and G2 Bottom plate Dimension drawings...

  • Page 151: Frames G1 And G2 - Air Baffles

    – Frames G1 and G2 Air baffles Dimension drawings...
  • Page 152 Dimension drawings...

  • Page 153: Example Circuit Diagram

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

  • Page 154: Example Circuit Diagram

    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 (* plus code options, ** other options, *** to be acquired by the customer). Example circuit diagram...

  • Page 155: Resistor Braking

    Availability of brake choppers and resistors Brake choppers are optionally available as built-in units, indicated in the type description by +D150. External resistors are available on request from ABB. When is resistor braking needed Typically, a drive system is equipped with brake choppers and resistors if: •...

  • Page 156: Placing The Brake Resistors

    A resistor other than the standard resistor can be used provided that: • its resistance is not lower than the resistance of the standard resistor WARNING! Never use a brake resistor with a resistance below the value specified for the particular drive / brake chopper / resistor combination. The drive and the chopper are not able to handle the overcurrent caused by the low resistance.

  • Page 157: Protecting The System In Fault Situations

    (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. Thermal switch Digital input of the JCU control unit.

  • Page 158: Maximum Cable Length

    The maximum length of the resistor cable(s) is 10 m (33 ft). EMC compliance of the complete installation Note: ABB has not verified that the EMC requirements are fulfilled with external user-defined brake resistors and cabling. The EMC compliance of the complete installation must be considered by the customer.

  • Page 159: Technical Data

    Drive module type Internal brake Example brake resistors chopper Type * brcont Rcont (kW) (ohm) (ohm) (kJ) (kW) 380…500 V ACS850-04-387A-5 2 × SAFUR125F500 7200 ACS850-04-500A-5 2 × SAFUR125F500 7200 ACS850-04-580A-5 2 × SAFUR200F500 1.35 10800 ACS850-04-650A-5 2 × SAFUR200F500 1.35...

  • Page 160: Dimensions And Weights

    Dimensions and weights Brake resistor Weight type (kg) SAFUR125F500 SAFUR200F500 ght: FUR180F460: 32 kg FUR125F500: 25 kg FUR200F500: 30 kg FUR210F575: 27 kg 5 5 Ø 7 Resistor braking...

  • Page 161: What This Chapter Contains

    When is du/dt filter needed? See section Checking the compatibility of the motor and drive, page 50. Selection table du/dt filter types for the drive module types are given below. Drive module type du/dt filter type ACS850-04-387A-5 FOCH0610-70 ACS850-04-500A-5 FOCH0610-70 ACS850-04-580A-5 FOCH0610-70 ACS850-04-650A-5 FOCH0610-70...
  • Page 162 du/dt filters...

  • Page 163: Product And Service Inquiries

    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 164 Contact us www.abb.com/drives www.abb.com/drivespartners...

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