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Hardware Manual
ACS800-07LC Drives
ACS800 liquid-cooled single drive manuals
2)
OPTION MANUALS
Manuals for Fieldbus Adapters, I/O Extension Modules etc.
1)
Always included in the delivery
2)
Included in the delivery with appropriate program or option device
3)
Included in the delivery with the optional liquid-cooling unit
ACS800-07LC Drives
Hardware Manual
3AFE68620902 Rev B
EN
EFFECTIVE: 24.10.2006
Safety instructions
Safety instructions
6
WARNING!
• Only qualified electricians are allowed to install and maintain the drive!
• Before working on the input cubicle, isolate the whole drive from the supply. The
main disconnector of the drive does not remove the voltage from the input
busbars of the drive.
• Never work on the drive, motor cable or motor when main power is applied. After
disconnecting the input power, always wait for 5 minutes to let the intermediate
circuit capacitors discharge before you start working on the drive, motor or motor
cable. Measure the voltage between power terminals and earth with a multimeter
(impedance at least 1 Mohm) to ensure that the drive is discharged before
beginning work.
• Apply temporary grounding before working on the unit.
• Do not work on the control cables when power is applied to the drive or to the
external control circuits. Externally supplied control circuits may carry dangerous
voltage even when the main power of the drive is switched off.
• When joining shipping splits (if any), check the cable connections at the joints
before switching on the supply voltage.
• Live parts inside the cubicle are protected against direct contact. However, pay
special attention when handling metallic shrouds.
• Do not make any insulation resistance or withstand voltage tests on the drive or
drive modules.
• Isolate the motor cables from the drive when testing the insulation resistance of or
withstand voltage of the cables or the motor.
• When reconnecting the motor cable, always check that the phase order is correct.
Note:
• The motor cable terminals on the drive are at a dangerously high voltage when
the input power is on, regardless of whether the motor is running or not.
• The drive DC bus carry a dangerous voltage (over 500 V).
• Depending on the external wiring, dangerous voltage (115 V, 220 V or 230 V) may
be present on the relay outputs of the drive system.
• The Prevention of Unexpected Start function does not remove the voltage from
the main and auxiliary circuits.
Safety instructions
7
WARNING!
• Use extreme caution when manoeuvring heavy inverter, supply or filter modules.
• Beware of hot surfaces. Some parts inside the drive cabinet, such as heatsinks of
power semiconductors, remain hot for a while after the disconnection of the
electrical supply.
• Make sure that dust from drilling does not enter the drive when installing.
Electrically conductive dust inside the unit may cause damage or lead to
malfunction.
• Recommendation: Do not fasten the cabinet by riveting or welding. However, if
welding is necessary, ensure that the return wire is properly connected close to
the weld in order not to cause damage to the electronic equipment in the cabinet.
Also ensure that welding fumes are not inhaled.
Grounding
These instructions are intended for all who are responsible for the grounding of the
drive. Incorrect grounding can cause physical injury, death or equipment malfunction
and increase electromagnetic interference.
WARNING!
• Ground the drive, the motor and adjoining equipment to ensure personnel safety
in all circumstances, and to reduce electromagnetic emission and pick-up.
• Make sure that grounding conductors are adequately sized as required by safety
regulations.
• In a multiple-drive installation, connect each drive separately to protective
earth (PE).
• Do not install a drive equipped with an EMC (line) filter (option +L202) 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.
Safety instructions
8
WARNING!
• Before using the winch for the first time, spool out 2 metres (6 feet) of cable, then
rewind the cable onto the drum keeping enough tension on the cable to make
sure no slack is left on the drum.
• When lowering the module, keep in mind that any slack on the winch may cause
the module to suddenly drop for several centimetres.
• After using the winch, rewind the cable onto the drum keeping enough tension on
the cable to make sure no slack is left on the drum.
WARNING!
• Beware of hot liquid. Do not work on the liquid cooling system until the pressure is
lowered down by stopping the pumps. High-pressure warm coolant is present in
the internal cooling circuit when it is in operation.
• Before power switch-on, make sure that the internal cooling circuit is filled up with
coolant. Running the pump dry will damage it. Also the drive will not cool down.
• Units with a liquid cooling unit option (+C139, +C140, +C141): Do not open
the pump inlet or outlet valves before filling up the internal cooling circuit. The
pumps are prefilled with a water-glycol-inhibitor mixture to prevent corrosion and
the valves are closed at the factory.
• Avoid skin contact with coolant, especially antifreeze. Do not syphon them by
mouth. If such substance is swallowed or gets into the eyes, seek medical advice.
• Do not overtighten the outer union of the nuts of the liquid
hoses - leave 2 to 3 mm of thread visible. Overtightening will
break the hose. 2 mm
Safety instructions
9
WARNING! Handle the fibre optic cables with care. When unplugging optic cables,
always grab the connector, not the cable itself. Do not touch the ends of the fibres
with bare hands as the fibre is extremely sensitive to dirt. The minimum allowed
bend radius is 35 mm (1.38 in.).
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. The drive can be adjusted to operate the motor at speeds
above and below the speed provided by connecting the motor directly to the
power line.
• The doors of the drive must be kept locked when the drive is in operation.
• Before power switch-on, make sure that the liquid cooling circuit is filled up with
coolant. Running the pump dry will damage it. Also the drive will not cool down.
• Do not control the motor with the disconnecting device (means); instead, use the
control panel keys and , or commands via the I/O board of the drive. The
maximum allowed number of charging cycles of the DC capacitors (i.e. power-ups
by applying power) is five in ten minutes.
Note:
• If an external source for start command is selected and it is ON, the drive will start
immediately after fault reset unless the drive is configured for a pulse-start/stop
by a parameter.
• When the control location is not set to Local (L not shown in the status row of the
display), the stop key on the control panel will not stop the drive. To stop the drive
using the control panel, press the LOC/REM key and then the stop key .
Safety instructions
10
WARNING! Do not work on the drive when the permanent magnet motor is rotating.
Also, when the supply power is switched off and the inverter is stopped, a rotating
permanent magnet motor feeds power to the intermediate circuit of the drive and the
supply connections become live.
Before installation and maintenance work on the drive:
• Stop the motor.
• Ensure that the motor cannot rotate during work.
• Prevent the start-up of the motors coupled to the same mechanical system and
ensure that no other system can rotate the motor.
• Ensure that there is no voltage on the drive power terminals:
Alternative 1) Disconnect the motor from the drive with a safety switch or by other
means. Measure that there is no voltage present on the drive input or output
terminals (U1, V1, W1, U2, V2, W2, UDC+, UDC-).
Alternative 2) Measure that there is no voltage present on the drive input or output
terminals (U1, V1, W1, U2, V2, W2, UDC+, UDC-). Ground the drive output
terminals temporarily by connecting them together as well as to the PE.
Alternative 3) If possible, both of the above.
WARNING! Do not run the motor over the rated speed. Motor overspeed leads to
overvoltage which may damage or explode the capacitors in the intermediate circuit
of the drive.
Controlling a permanent magnet motor is only allowed using the ACS800 Permanent
Magnet Synchronous Motor Drive Application Program, or other application
programs in scalar control mode.
Safety instructions
11
Table of contents
Safety instructions
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Usage of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Use of the hand-operated winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Work on the liquid cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Printed circuit boards and fibre optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Start-up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Table of contents
Hardware description
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Operation basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Overview – 6 or 12-pulse drive with modules 1×D4+2×R8i, no built-in main contactor or breaker (no
option +F255 or +F250) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Overview – 6-pulse drive with modules 2×D4+4×R8i and a built-in main breaker (option +F255) . 26
Swing-out frame in the supply module cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Swing-out frame in the inverter module cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Cabling direction options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Single-line circuit diagram of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Door switches and control panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Supply unit control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Connections and use of the IO in the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Connections to standard I/O terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Table of contents
12
Mechanical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Checking the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Moving the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
…by crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
…by fork-lift or pallet truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
…on rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Final placement of the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Installation procedure - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Fastening the cabinet to the floor (Non-marine units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Using the holes inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Fastening the unit to the floor and wall (Marine units, option +C121) . . . . . . . . . . . . . . . . . . . . . . .48
Joining the shipping splits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Preparations for the liquid pipe connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Fastening the cabinets together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Connecting the liquid pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Connecting the PE busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Connecting the DC busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Cable duct in the floor below the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Electric welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Table of contents
13
Electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Input cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Checking the compatibility with IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Input power and charging circuit connection – drives without a built-in main breaker (no option +F255)
or contactor (+F250) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Connection diagram – 6-pulse units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Connection diagram – 12-pulse units (option +A004) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Connection diagram – 18-pulse units (option +A005) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Connection diagram – 24-pulse units (option +A006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Connection procedure – 6-pulse to 24-pulse units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Input power connection – drives with built-in main breaker (option +F255) or
contactor (option +F250) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Connection diagram – 6-pulse units (option +F255 or +F250) . . . . . . . . . . . . . . . . . . . . . . . 82
Connection diagram – 12-pulse units (options +A004 and +F255 or +F250) . . . . . . . . . . . . 83
Connection diagram – 18-pulse units (options +A005 and +F255 or +F250) . . . . . . . . . . . . 84
Connection diagram – 24-pulse units (options +A006 and +F255 or +F250) . . . . . . . . . . . . 85
Connection procedure – 6- to 24-pulse units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Table of contents
14
Motor connection – Frame R8i without the Common Motor Terminal cubicle (no option +H359) or
Common Motor Terminal connection (no option +H366) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Connection diagram – single inverter module feeds one motor . . . . . . . . . . . . . . . . . . . . . . .87
Connection diagram – parallel inverter modules feed one motor . . . . . . . . . . . . . . . . . . . . . .87
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Motor connection – Units with the Common Motor Terminal connection (option +H366) . . . . . . . .91
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Motor connection – Units with the Common Motor Terminal cubicle (option +H359) . . . . . . . . . . .92
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Connection of external power supply for the auxiliary circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Connection diagram, case 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Connection diagram, case 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
External control connections to the inverter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
IO connection diagram (non-US version of the Standard Application Program) . . . . . . . . . . .97
IO connection diagram (US version of the Standard Application Program) . . . . . . . . . . . . . .98
External control connections to the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Control cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Installation of optional modules and PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
PC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Installation of option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Cabling of I/O and fieldbus modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Cabling of pulse encoder interface module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Fibre optic links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Installation checklist
Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Start-up
Basic checks with no voltage connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Connecting voltage to input terminals and auxiliary circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Starting the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Checks with the supply unit running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Inverter unit application program set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
On-load checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Fault tracing
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
LEDs of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Maintenance
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Table of contents
15
Table of contents
16
Technical data
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Output frequency derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Auxiliary circuit current consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Type equivalence tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
Supply and inverter units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
ACS800-07LC frame sizes and power module types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Losses and cooling circuit data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
Supply unit AC and DC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Inverter unit DC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Input busbar and lead-through data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
Units without built-in main breaker or contactor (no option +F250 or +F255) . . . . . . . . . . . .150
Units with built-in main breaker (option +F255) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Units with built-in main contactor (option +F250) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Motor cable busbar and lead-through data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
Units without the Common Motor Terminal cubicle (no option +H359) . . . . . . . . . . . . . . . . .152
Units with the Common Motor Terminal (CMT) cubicle (option +H359) . . . . . . . . . . . . . . . .153
Input power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Transformer for a 12-, 18- and 24 -pulse supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
Internal cooling circuit data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
Tightening torques for power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Compliance with the EN 61800-3 (2004), category C2 . . . . . . . . . . . . . . . . . . . . . . . .158
Compliance with the EN 61800-3 (2004), category C3 . . . . . . . . . . . . . . . . . . . . . . . .159
Compliance with the EN 61800-3 (2004), category C4 . . . . . . . . . . . . . . . . . . . . . . . .159
Compliance with the Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
UL and CSA markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
UL and CSA notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Patent protection in the USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Table of contents
17
Table of contents
18
Table of contents
19
Target audience
This manual is intended for people who plan the installation, install, commission, use
and service the drive. Read the manual before working on the drive. The reader is
expected to know the fundamentals of electricity, wiring, electrical components and
electrical schematic symbols.
The manual is written for readers worldwide. Both SI and imperial units are shown.
Special US instructions for installations within the United States that must be
installed per the National Electrical Code and local codes are marked with (US).
Contents
The chapters of this manual are briefly described below.
Safety instructions contains safety instructions for the installation, commissioning,
operation and maintenance of the drive.
About this manual introduces this manual.
Hardware description describes the main parts of the drive.
Mechanical installation instructs how to move, place and mount the drive.
Planning the electrical installation provides advice on motor and cable selection, the
protective functions of the drive, and cable routing.
Electrical installation describes the cabling and wiring of the drive.
Motor control and I/O board (RMIO) specification shows the control board
specifications.
Installation checklist helps in checking the mechanical and electrical installation of
the drive.
Start-up guides through the drive start-up procedure.
Maintenance contains preventive maintenance instructions and instructs in supply
and inverter module replacement.
Fault tracing contains troubleshooting instructions.
Technical data 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 policy.
Dimensions and weights contains information on the dimensions of the drive.
The internal cooling circuit contains information on the drive internal cooling system.
Task See
Plan the installation. Check: ambient conditions, ratings, Technical data, page 141
required external cooling circuit arrangements, input power Planning the electrical installation, page 55
connection, compatibility of the motor, motor connection,
Option manuals (if optional equipment is included)
etc.
Select the cables.
If the drive is about to be connected to an IT (ungrounded) Contact your local ABB representative for a separate
system, check that the drive is not equipped with EMC/RFI instruction.
filtering +E202.
Check that all necessary optional modules and equipment
are present and correct.
If the converter has been non-operational for more than one Contact your local ABB representative.
year, reform the converter DC link capacitors.
Check the insulation of the motor and the motor cable. Checking the insulation of the assembly, page 75
Connect the power cables. Connect the control and the Electrical installation, page 75
auxiliary control cables.
Commission the drive. Start-up, page 105 and appropriate firmware manual
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 Oy, AC Drives, PO Box 184, 00381 Helsinki,
Finland.
Other manuals
See the inside of the front cover.
Hardware description
Operation basics
The ACS800-07LC is a cabinet-mounted liquid-cooled drive for controlling AC
motors.
The drive consists of several cubicles that contain: the input and motor cable
terminals, diode supply module(s), inverter modules, and various optional
equipment. The actual arrangement of the cubicles varies depending on the drive
type and selected options. See the chapter Dimensions and weights for the different
line-up variations.
Hardware description
24
Hardware description
25
1 2 9
10
8
7
11
6 12
3 13
5
15 16
4
14
Hardware description
26
Hardware description
27
Doors closed
4 1 2 11
12 12
10 10
9
9
13
14
15
7
8 8
5 16 16
18 19
6 17 17
Hardware description
28
No. Description
8. Terminal block X1
4 5 6
9. Earth (ground) fault monitoring unit (optional)
3 1
Hardware description
29
7 8 9 No. Description
Layout of the swing-out frame for inverter cubicle with modules (2×R8i or 3×R8i).
Note that the layout differs slightly in the narrower 1×R8i cubicle.
Hardware description
30
Note: Not all option combinations given above are available for all drive types.
Check the availability with ABB.
Hardware description
Diode supply module Inverter modules DC bus
Brake choppers3)
Brake resistors4)
M M M
M
Single-line circuit diagram of the drive
Main breakers1)
U<
4)
Main supply
U<
(12-pulse) M
3~
Hardware description
31
32
2 3 1 4
Hardware description
33
Control
Control panel
board (RMIO)
Communication module 1: IO extension (RAIO, RDIO)
Slot 1 or fieldbus adapter (e.g. RMBA, RDNA, RPBA).
Optional device. 1)
Installed as standard.
STOP
RESET
Supply Unit Inverter unit. PC, IO modules,
Supply unit control circuitry: Measuring Connected by fieldbus adapter.
door switches, main breaker control, Adapter (NAIO- default. See Optional
etc. 03F). Installed Inverter unit device.
as standard. control
2) interfaces on
DSCB page 37.
2)
= ~ To motor
Input power
~ =
Supply module(s) Inverter module(s)
1)
RDIO Digital IO Extension Module is installed to option Slot 1 as standard in units with parallel supply modules.
The control program receives the ready acknowledgement signals of each module through the RDIO inputs.
For details about the interconnections of the boards, see ACS800 Liquid-cooled Supply Control Program Firmware
Manual (3AFE68746299 [English]) and the circuit diagrams delivered with the drive.
Hardware description
34
Hardware description
35
Control circuitry 3 AI1+ VDC MEASURING. 0(2)…10 V, Rin > 200 kohm
DSCB board 4 AI1-
Operating switch
5 AI2+ I SUM TOT. 0(4)…20 mA, R in = 100 ohm
1 3
6 AI2-
7 AI3+ I SUM MAX . 0(4)…20 mA, Rin = 100 ohm
2 4
8 AI3-
0
1 9 AO1+ Not in use. 0(4)…20 mA, RL < 700 ohm
START
10 AO1-
Main breaker 11 AO2+ Not in use. 0(4)…20 mA, RL < 700 ohm
12 AO2-
X22
1 DI1 ALARM / FAULT
2 DI2 ON / OFF
Charging contactor
3 DI3 ACK MAIN CONTACTOR
4 DI4 EARTH FAULT
5 DI5 ALARM / FAULT
6 DI6 RESET
7 +24V +24 VDC max. 100 mA
For details, see the delivery specific 8 +24V
circuit diagrams of the cabinet-installed 9 DGND1 Digital ground
unit. The diagrams show:
10 DGND2 Digital ground
- supply unit on/off control
11 DIIL Not in use
- main breaker supervision and on/off
control X23
- charging contactor on/off control 1 +24V Auxiliary voltage output, non-isolated, 24 VDC
2 GND 250 mA
- optional auxiliary circuit wiring.
X25
WARNING! Never force the main 1 RO1 Charging contactor control: Open (0) /
breaker closed before charging has 2 RO1 close (1)
been completed. Starting sequence, i.e. 3 RO1
charging, acknowledgements, main
X26
contactor control and the supply unit
start, follows a certain order. Never 1 RO2 LCU control: Off (0) / on (1)
change the order by by-passing signals 2 RO2
(using jumpers), etc. That will cause a 3 RO2
malfunction that may damage the unit. X27
1 RO3 Main breaker control: open (0) /
2 RO3 close (1)
3 RO3
Hardware description
36
= ~
To motor
Input power
~ =
Supply module(s) Inverter module(s)
Hardware description
37
Type code
The type code of the drive is indicated on the type designation label, attached on the
door of the drive (inside). The type code contains a summary of the configuration of
the drive. The first digits from left express the basic configuration e.g.
ACS800-07LC-0560-7. The optional selections are given thereafter, separated by
plus signs, e.g. +G304. The selections are described below.
Note: The information below is for quick reference only and does not contain all
conditions and details. For more information, contact the local ABB representatives.
Basic code
Digit Name/Description Alternatives
1…6 Product series ACS800
8…11 Product type 07LC – cabinet-installed liquid-cooled drive.*
13…16 Size 0390...6620
18 Voltage rating 4 – Voltage range 380…415 VAC
5 – Voltage range 440…500 VAC
7 – Voltage range 525…690 V
* When no options are selected, the following features are included as standard: 6-pulse supply
connection, +B054 (IP42, UL type 1, NEMA 1), +G320 (230 VAC), +A012 (Supply frequency 50 Hz),
+J400 (CDP312R control panel),+E210 (EMC 2nd environment), +E205 (du/dt limitation at drive
output), +E208 (common mode filters), +N664 (Standard Application Program), +H367 (control cabling
bottom entry/exit), +H350 (bottom power cabling entry), +H352 (Bottom power cabling exit), +G315 (tin
plated copper DC-busbars), coated circuit boards, +R700 (set of English manuals), cable lead through
entry, IEC approved components, RDCO-03. Note: These option codes are not shown on the
nameplate.
Hardware description
38
Code Description
Liquid cooling unit 2, nominal cooling capacity 195 kW,
C141 Redundant pump cooling unit (capacity 195kW)
C139 Stand-alone version
C142 Bottom pipe connection
C144 Pipe connection on left (not with C139)
C145 ANSI flanges
C146 Sea water heat exchanger (requires C139)
Z1140 380-415 V/50 Hz external supply voltage (pump)
Z1150 660-690 V/50 Hz external supply voltage (pump)
Z1160 380-440 V/60 Hz external supply voltage (pump)
Z1180 660-690 V/60 Hz external supply voltage (pump)
C147 3-way valve, outside cabinet
Resistor braking
D150 Braking chopper (1 to 6 pcs)
D151 Braking resistor in separate cabinet
Filters
E202 EMC/RFI-filter, 1st environment, restricted (A-limits, earthed network) up to 1000A
E206 Sine output filter
Line options
F250+ Line contactor and switch fuse
F254
F255 Air circuit breaker
F259 Earthing switch (requires air circuit breaker or line contactor, not available with C129)
F269 Inverter output contactors (not available with H366, H359, E206)
F271 Output earthing terminals (requires common motor terminal cubicle, add H366)
Control voltage
G304 115 VAC control voltage
G344 Auxiliary transformer
G307 Terminals for external control voltage 230VAC or 115VAC (UPS)
Cabinet options
G300 Cabinet heater (External supply)
G313 Output for motor heater (External supply)
G317 Busbar supply conductors (requires F255 or F250)
G330 Halogen free wiring and materials
Electrical options
Q954 Earth fault monitoring, IT
Q953 Earth fault monitoring, TN
G335 A-meter in one phase
3G335 A-meter in three phases
G332 Electrical disconnect push button on the door (black)
G334 V-meter with selector
G336 Arc monitoring (Rea) (Specify configuration separately)
G337 Arc monitoring with current sensing unit
Cabling
H351 Top entry
H353 Top exit
H365 Cable gland plates (Brass 6mm, undrilled)
H364 Cable gland plates (Aluminium 3mm, undrilled
H358 Cable gland plates (Steel 3mm, undrilled)
H366 Common motor terminal connection (2× and 3× R8iLC)
H359 Common motor terminal cubicle
Fieldbus
K451 DeviceNet adapter
K452 LONWorks adapter
K454 Profibus-DP adapter
K458 Modbus adapter
K462 ControlNet
K453 Interbus-S
K455 Modbus Plus
K456 AF100
K457 CANOpen
Hardware description
39
Code Description
I/O options
L500 Analogue I/O extension
L501 Digital I/O extension
L502 Pulse encoder interface
L509 DDCS communication 2
L508 DDCS communication 1
L504 Additional I/O-terminal block
L505 Thermistor relay (1 or 2 pcs)
L506 Pt100 relay (3, 5 or 8 pcs)
L513 ATEX certified thermal protection with PTC
Starter for auxiliary Motor fan
M602 2,5...4 A
M603 4...6,3 A
M604 6,3...10 A
M605 10...16 A
M606 16...25 A
Software
N650 Pump and fan control (PFC)
N651 Master/follower
N652 Crane control
N653 Application program template
N654 Spinning control
N666 Extruder control
N668 Traverse control
N669 Centrifuge control
N671 System application
N682 Multi block programming
Specialities
P902 Customised (described in technical appendix)
P904 Extended warranty
P913 Special colour (Described in Technical appendix)
Safety features
Q950 Prevention of unexpected start-up
Q951 Emergency stop, stop category 0
Q952 Emergency stop, stop category 1
G331 Emergency stop push button on the door (red)
Q959 Supply transformer breaker disconnect push button (red) on the door
Documentation language
R700 English
R701 German
R702 Italian
R703 Dutch
R704 Danish
R705 Swedish
R706 Finnish
R707 French
R708 Spanish
R709 Portuguese (in Portugal)
R711 Russian
Hardware description
40
Hardware description
41
Mechanical installation
Required tools
The tools required for moving the unit to its final position, fastening it to the floor and
tightening the connections are listed below.
• crane, fork-lift or pallet truck (check load capacity!); iron bar, jack and rollers
• Pozidrive and Torx (2.5–6 mm) screwdrivers for the tightening of the frame
screws
• torque wrench
• set of wrenches or sockets for joining shipping splits.
Mechanical installation
42
…by crane
Use the steel lifting bars attached to the top of the cabinet. Insert
the lifting ropes or slings into the holes of the lifting bars.
The lifting bars can be removed (not mandatory) once the cabinet
is in its final position. If the lifting bars are removed, the bolts
must be refastened to retain the degree of protection of the
cabinet.
Mechanical installation
43
…on rollers
(Not allowed with Marine versions)
Mechanical installation
44
Before installation
Delivery check
The drive delivery contains:
• drive cabinet line-up
• optional modules (if ordered) installed into the control rack at the factory
• winch for the supply and inverter module replacement
• appropriate drive manuals and optional module manuals
• delivery documents.
Check that there are no signs of damage. Before attempting installation and
operation, check the information on the type designation label of the drive to verify
that the delivery is of the correct type. The label includes input and output ratings,
markings, a type code and a serial number, which allow individual recognition of
each unit. For the type code key, see Type code on page 37. The first digit of the
serial number refers to the manufacturing plant. The next four digits refer to the unit’s
manufacturing year and week respectively. The remaining digits complete the serial
number so that there are no two units with the same serial number.
The type designation label of ACS800-07 LC drive is located on the supply unit door.
In ACS800 multidrive, each unit has a label of its’ own.
Each power module (i.e. supply and inverter module) is also individually labelled.
Mechanical installation
45
6a
6b
Mechanical installation
46
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. The recommended maximum
distance between the clamps is 800 mm (31.5”).
If there is not enough working space behind the cabinet for mounting, replace the
lifting bars at the top with L-brackets (not included) and fasten the top of the cabinet
to the wall.
Slot detail, front view
(dimensions in millimetres)
L-bracket
M16 screw
Cabinet top
Mechanical installation
47
L-bracket
M16 screw
25 mm (0.985”)
Cabinet top
Mechanical installation
48
Fastening the unit to the floor and wall (Marine units, option +C121)
The unit must be fastened to the floor and roof (wall) as follows:
2 3
L-bracket
Back panel of cabinet
Clamps (not
included in M16 bolt
delivery)
Flat bars at base of cabinet
Cabinet
Clamping the cabinet to the Fastening the cabinet at the top with
floor at the back brackets (side view), example
Mechanical installation
49
7× 7×
Maximum tightening torque:
5 Nm (3 ft.-lbs)
Mechanical installation
50
1 2
Axial gap: 5 to 15 mm
(0.2” to 0.6”)
Parallel misalignment:
max 3 mm (0.2”)
M10 bolt
Tightening torque:
35–40 Nm (25–30 ft.-lbs.)
Strength class: 8.8
Plain washer
Spring washer
Plain washer
Mechanical installation
51
a
a = joint piece
a
a
Nut
a a
WARNING! Do not place the spring washer against the joint piece. Use the plain
washer (with electroplated zinc coating and blue passivation) instead. An
unpassivated zinc-coated spring washer positioned directly against the joint piece
would cause corrosion.
Mechanical installation
52
Miscellaneous
Front
50 mm 100 mm
Front
Mechanical installation
53
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 metres of the welding point.
Cabinets with flat bars at the base
• Weld only the flat bar under the cabinet, never the cabinet frame itself.
• Clamp the welding electrode onto the flat bar about to be welded or to the next flat
bar of the cabinet (within 0.5 metres of the welding point).
WARNING! If the welding return wire is connected improperly, the welding circuit
may damage electronic circuits in the cabinet. The thickness of the zinc coating of
the cabinet frame is 100 to 200 micrometres; on the flat bars the coating is
approximately 20 micrometres. Ensure that the welding fumes are not inhaled.
Mechanical installation
54
Mechanical installation
55
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.
4. Consult the motor manufacturer before using a motor in a drive system where the
motor nominal voltage differs from the AC power source voltage.
5. Ensure that the motor insulation system withstands the maximum peak voltage in
the motor terminals. See the Requirements table on page 57 for the required
motor insulation system and drive filtering.
Example 1: When the supply voltage is 440 V and the drive has a diode supply
and operates in motor mode only, the maximum peak voltage at the motor
terminals can be approximated as follows: 440 V × 1.35 × 2 = 1190 V. Check that
the motor insulation system withstands this voltage.
Example 2: When the supply voltage is 440 V and the drive is equipped with an
IGBT supply, the maximum peak voltage in the motor terminals can be
approximated as follows: 440 V × 1.41 × 2 = 1241 V. Check that the motor
insulation system withstands this voltage.
Requirements table
The following table shows how to select the motor insulation system and when an
optional ABB du/dt filter, insulated N-end (non-driven end) motor bearings and ABB
common mode filters are required. The motor manufacturer should be consulted
regarding the construction of the motor insulation and additional requirements for
explosion-safe (EX) motors. Failure of the motor to fulfil the following requirements
or improper installation may shorten motor life or damage the motor bearings.
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
Manufacturer
Abbreviation Definition
UN nominal voltage of the supply network
ÛLL peak line-to-line voltage at motor terminals which the motor insulation must withstand
PN motor nominal power
du/dt du/dt filtering at the output of the drive (option +E205)
CMF common mode filtering (option +E208)
N N-end bearing: insulated motor non-driven end bearing
n.a. Motors of this power range are not available as standard units. Consult the motor manufacturer.
the values of the graph by the supply voltage (UN). In case of drives with an IGBT supply unit or resistor
braking, the ÛLL and du/dt values are approximately 20% higher.
3.0
Û LL/UN
2.5
2.0
du/dt
------------- (1/μs) With du/dt Filter
UN
1.5
1.0
0.5
0.0
100 200 300
Cable length (m)
Note: The EMC filter (if present) includes capacitors connected between the main
circuit and the frame. These capacitors and long motor cables increase the earth
leakage current and may cause fault current circuit breakers to function.
WARNING! The prevention of unexpected start function does not disconnect the
voltage of the main and auxiliary circuits from the drive. Therefore maintenance work
on electrical parts of the drive can only be carried out after isolating the drive system
from the main supply.
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 on page 141 for the rated currents.
• The cable must be rated for at least 70°C maximum permissible temperature of
conductor in continuous use. For US, see Additional US requirements on
page 68.
• The inductance and impedance of the PE conductor/cable (grounding wire) must
be rated according to permissible touch voltage appearing under fault conditions
(so that the fault point voltage will not rise excessively when a ground fault
occurs).
• 600 VAC cable is accepted for up to 500 VAC. For 690 VAC rated equipment, the
rated voltage between the conductors of the cable should be minimum 1 kV.
For motors larger than 30 kW, symmetrical shielded motor cable must be used (see
figure on page 67). A four-conductor system can be used up to 30 kW motors, but
shielded symmetrical motor cable is recommended.
A four-conductor system is allowed for input cabling, but shielded symmetrical cable
is recommended. To operate as a protective conductor, the shield conductivity must
be as follows when the protective conductor is made of the same metal as the phase
conductors:
Cross-sectional area of the phase Minimum cross-sectional area of the
conductors corresponding protective conductor
S (mm2) Sp (mm 2)
S < 16 S
16 < S < 35 16
35 < S S/2
Note: The configuration of the drive may require multiple supply and/or motor
cabling (e.g. diode supply module has two parallel bridges that need to be supplied
separately). Refer to the connection diagrams in chapter Electrical installation.
The motor cable and its PE pigtail (twisted screen) should be kept as short as
possible in order to reduce electromagnetic emission as well as capacitive current.
Recommended
Symmetrical shielded cable: three phase conductors A separate PE conductor is required if the conductivity
and a concentric or otherwise symmetrically of the cable shield is < 50% of the conductivity of the
constructed PE conductor, and a shield phase conductor.
PE conductor Shield
and shield Shield
PE
PE
PE Shield
A four-conductor system:
three phase conductors
and a protective
conductor.
Not allowed for motor cables Not allowed for motor cables with phase
conductor cross section larger than 10 mm 2
(motors > 30 kW).
Cable core
Additional US requirements
Type MC continuous corrugated aluminium armor cable with symmetrical grounds or
shielded power cable must be used for the motor cables if metallic conduit is not
used. For the North American market, 600 VAC cable is accepted for up to 500 VAC.
1000 VAC cable is required above 500 VAC (below 600 VAC). For drives rated over
100 amperes, the power cables must be rated for 75°C (167°F).
Conduit
Where conduits must be coupled together, bridge the joint with a ground conductor
bonded to the conduit on each side of the joint. Bond the conduits also to the drive
enclosure. Use separate conduits for input power, motor, brake resistors, and control
wiring. When conduit is employed, type MC continuous corrugated aluminium armor
cable or shielded cable is not required. A dedicated ground cable is always required.
Note: Do not run motor wiring from more than one drive in the same conduit.
Case 1 +G344 Yes Drive has auxiliary voltage Transformer supplies fans. No need for external
transformer which is supplied power supply.
by drive main AC power line.
+G307 No Drive has no terminals for Transformer supplies control circuitry. No need for
external control voltage (UPS). external power supply.
Case 2 +G344 Yes Drive has auxiliary voltage Transformer supplies fans. No need for external
transformer which is supplied power supply.
by drive main AC power line.
+G307 Yes Drive has terminals for external Arrange external power supply for control circuitry:
control voltage (UPS). - See section Connection of external power supply for
the auxiliary circuits on page 94 for connection.
- Calculate load using data given in section Auxiliary
circuit current consumption on page 143. Consider
only “non-fan” load.
Case 3 +G344 No Drive has no auxiliary voltage Arrange external power supply for fans and control
transformer. circuitry:
- See section Connection of external power supply for
+G307 No Drive has no terminals for
the auxiliary circuits on page 94 for connection.
external control voltage (UPS).
- Calculate load using data given in section Auxiliary
circuit current consumption on page 143.
Case 4 +G344 No Drive has no auxiliary voltage Arrange external power supply for fans:
transformer. - See section Connection of external power supply for
the auxiliary circuits on page 94 for connection.
- Calculate load using data given in section Auxiliary
circuit current consumption on page 143. Consider
only fan load.
+G307 Yes Drive has terminals for external Arrange external power supply for control circuitry:
control voltage (UPS). - See section Connection of external power supply for
the auxiliary circuits on page 94 for connection.
- Calculate load using data given in section Auxiliary
circuit current consumption on page 143. Consider
only “non-fan” load.
If there are power factor compensation capacitors in parallel with the 3-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.
2. If capacitor load is increased/decreased step by step when the AC drive is
connected to the power line, ensure that the connection steps are low enough not
to cause voltage transients that would trip the drive.
3. Check that the power factor compensation unit is suitable for use in systems with
AC drives i.e. harmonic generating loads. In such systems, the compensation unit
should typically be equipped with a blocking reactor or harmonic filter.
WARNING! Never connect the supply power to the drive output terminals U2, V2
and W2. If frequent bypassing is required, employ mechanically connected switches
or contactors. Mains (line) voltage applied to the output can result in permanent
damage to the unit.
Relay outputs
Varistor
RO (NC)
RO (C)
230 VAC
RO (NO)
RC filter
RO (NC)
230 VAC RO (C)
RO (NO)
Diode
RO (NC)
24 VDC RO (C)
RO (NO)
a b
Double-shielded twisted Single-shielded twisted
pair cable multipair cable
Relay cable
The cable type with braided metallic screen (e.g. ÖLFLEX from Lapp Kabel,
Germany) has been tested and approved by ABB.
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.
Motor cable
Drive
min. 300 mm (12 in.)
Power cable
Control cables
Not allowed unless the 24 V cable is insulated Lead 24 V and 230/120 V control cables
for 230 V (120 V) or insulated with an in separate ducts into the inside of the
insulation sleeving for 230 V (120 V). cabinet.
Electrical installation
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.
Before installation
Checking the insulation of the assembly
WARNING! Before start, read and follow the instructions given in chapter Safety
instructions. Ignoring the instructions can cause physical injury or death, or damage
to the equipment.
Drive
Every drive has been tested for insulation between the main circuit and the chassis
(2500 V rms 50 Hz for 1 second) at the factory. Therefore, do not make any voltage
tolerance or insulation resistance tests (e.g. hi-pot or megger) on any part of the
drive.
Input cable
Check the insulation of the input cable according to local regulations before
connecting it to the drive.
Motor and motor cable
Check the insulation of the motor and motor cable as follows:
• Check that all motor cables are disconnected from the drive output terminals U2,
V2 and W2.
M • Measure the insulation resistance of the motor cable and motor between each
ohm
phase and the Protective Earth by using a measuring voltage of 1 kV DC. The
PE insulation resistance must be higher than 1 Mohm.
Electrical installation
76
Bridging is installed
at the factory for a
6-pulse unit. Do not
remove!
max. 50 A
1)
1L1.1
1L2.1
1L3.1
1L1.2
1L2.2
1L3.2
10 mm2
PE
Q2.1
3
Q2.2
Charging circuit 1)
Notes:
1) With a half-controlled input bridge (option +A018), no charging circuit and no external wiring for it are needed.
The figure shows the connection of a supply unit with one D4 module. The connection principle is the same with D3 (then
the module contains only one bridge) and multiple modules.
The main breaker is to be acquired and installed by the customer.
For selection of the input power cables, see chapter Selecting the power cables on page 72
For the power cable terminal sizes and cabinet lead-through sizes, see section Units without built-in main breaker or
contactor (no option +F250 or +F255) on page 150.
For the power cable terminal tightening torques, see section Connection procedure – 6-pulse to 24-pulse units on
page 80.
Electrical installation
77
U<
max. 50 A
10 mm2
1)
1L1.1
1L2.1
1L3.1
1L1.2
1L2.2
1L3.2
PE
Q2.1
3
Q2.2
Charging circuit 1)
Notes:
1)
With a half-controlled input bridge (option +A018), no charging circuit and no external wiring for it are needed.
The figure shows the connection of a supply unit with one D4 module. The connection principle is the same with multiple
modules.
Pay special attention to the connection of the two bridges inside each module. For a 12-pulse connection, bridge 1 and
bridge 2 must be supplied either from separate transformers or separate transformer secondary windings. For the supply
transformer specification, see section Transformer for a 12-, 18- and 24 -pulse supply on page 154.
The main breakers are to be acquired and installed by the customer.
For selection of the input power cables, see section Selecting the power cables on page 72.
For the power cable terminal sizes and cabinet lead-through sizes, see section Input busbar and lead-through data on
page 150.
For the power cable terminal tightening torques, see section Connection procedure – 6-pulse to 24-pulse units on page 80.
Electrical installation
78
U<
U<
U<
max. 50 A
1)
1L3.3
1L2.3
10 mm2
1L1.3
1L1.1
1L2.1
1L3.1
1L1.2
1L2.2
1L3.2
PE
Q2.1
3
Q2.2
Charging circuit 1)
Supply
module
Supply module cubicle 1 DC bus cubicle 2
Notes:
1)
With a half-controlled input bridge (option +A018), no charging circuit and no external wiring for it are needed.
For the other notes, see section Connection diagram – 12-pulse units (option +A004) on page 77.
Electrical installation
79
U<
U<
U<
max. 50 A
10 mm2 1)
1L1.3
1L2.3
1L3.3
1L1.4
1L2.4
1L3.4
1L1.1
1L2.1
1L3.1
1L1.2
1L2.2
PE 1L3.2
Q2.1
3
Q2.2
Charging circuit 1)
Supply module
Supply module cubicle 1 DC bus cubicle 2
Notes:
1) With a half-controlled input bridge (option +A018), no charging circuit and no external wiring for it are needed.
For the other notes, see section Connection diagram – 12-pulse units (option +A004) on page 77.
Electrical installation
80
WARNING! Read and follow the instructions given in chapter Safety instructions.
Ignoring the instructions can cause physical injury or death, or damage to the
equipment.
1. Open the door of the supply module cubicle: Unlock the handle, release it from
the holder and turn upwards to release the door locking mechanism.
2. Remove the shroud that protect the input busbars and cable entries (four screws).
3. Unplug the socket of the cooling fan and remove the cooling fan. See section
Replacing the fan of the diode supply module cubicle on page 110 for instructions.
4. Units with charging resistors (no option +A018): Lead the charging circuit
cable into the inside of the cubicle to the appropriate terminal block, and connect.
5. Lead the input power cables into the inside of the cubicle. It is recommended to
apply 360° grounding of the cable shields at the entry.
6. Connect the input power cables:
- Cut the cables to suitable length. Strip the cables and conductors. Fasten
cable lugs to the conductor ends.
- Twist the cable shields into bundles and connect to cabinet PE (ground)
busbar. Connect also any separate ground conductors or cables to cabinet PE
busbar.
- Connect the phase conductors to the input power terminals. Depending on the
supply connection principle, see the appropriate connection diagram above.
- Tighten the phase conductors and PE to 70 Nm (50 lbf.ft) torque.
7. Refit the fan and plug in the fan socket.
8. Refit the shroud removed earlier and close the door.
Electrical installation
81
Lower half of the supply module cubicle from front, Supply module from below,
shroud removed, cooling fan in place shroud and cooling fan removed
3
6
Electrical installation
82
Input power connection – drives with built-in main breaker (option +F255)
or contactor (option +F250)
L3
PE
Charging circuit 1)
Notes:
1)
There is no charging circuit with a half-controlled input bridge (option +A018).
The figure shows the connection of a supply unit with one D4 module. The connection principle is the same with multiple
modules.
2) Units
with option +F250 have a contactor and a switch fuse (OESA) instead of a breaker.
For selection of the input power cables, see section Selecting the power cables on page 64.
For the power cable terminal sizes and cabinet lead-through sizes, see section Units with built-in main breaker (option
+F255) on page 151.
For the power cable terminal tightening torques, see section Connection procedure – 6- to 24-pulse units on page 86.
Electrical installation
83
U< 2)
1L1.2
1L2.2
1L3.2
PE U<
1L1.1
1L2.1
1L3.1
1)
Charging circuit 1)
Notes:
1)
There is no charging circuit with a half-controlled input bridge (option +A018).
2) Units with option +F250 have a contactor and a switch fuse (OESA) instead of a breaker.
The figure shows the connection of a supply unit with one D4 module. The connection principle is the same with multiple
modules.
Pay special attention to the connection of the two bridges inside each module. For a 12-pulse connection, bridge 1 and
bridge 2 must be supplied either from separate transformers or separate transformer secondary windings. For the supply
transformer specification, see section Transformer for a 12-, 18- and 24 -pulse supply on page 154
For selection of the input power cables, see chapter see section Selecting the power cables on page 64.
For the power cable terminal sizes and cabinet lead-through sizes, see section Input busbar and lead-through data on
page 150.
For the power cable terminal tightening torques, see section Connection procedure – 6- to 24-pulse units on page 86.
Electrical installation
84
2)
U<
1L1.3
1L2.3
1L3.3
PE
U<
1L1.2
1L2.2
1L3.2
PE
U<
1L1.1
1L2.1
1L3.1
1)
Charging circuit 1)
Notes:
1) There is no charging circuit with a half-controlled input bridge (option +A018).
2)
Units with option +F250 have a contactor and a switch fuse (OESA) instead of a breaker.
For the other notes, see section Connection diagram – 12-pulse units (options +A004 and +F255 or +F250) on page 83
Electrical installation
85
1L2.4
1L3.4
PE
U<
1L1.3
1L2.3
1L3.3
PE
U<
1L1.2
1L2.2
1L3.2
PE
U<
1L1.1
1L2.1
1L3.1
1)
Charging circuit 1)
Notes:
1)
There is no charging circuit with a half-controlled input bridge (option +A018).
2) Units
with option +F250 have a contactor and a switch fuse (OESA) instead of a breaker.
For the other notes, see section Connection diagram – 12-pulse units (options +A004 and +F255 or +F250) on page 83
Electrical installation
86
WARNING! Read and follow the instructions given in chapter Safety instructions.
Ignoring the instructions can cause physical injury or death, or damage to the
equipment.
1. Open the door of the incoming cubicle. Unlock the handle, release it from the
holder and turn upwards to release the door locking mechanism.
2. Remove the shroud that protect the input busbars and cable entries.
3. Lead the input cables into the inside of the cubicle. It is recommended to apply
360° grounding of the cable shields at the entry.
4. Connect the cables:
- Cut the cables to suitable length. Strip the cables and conductors. Fasten
cable lugs to the conductor ends.
- Twist the cable shields into bundles and connect to cabinet PE (ground)
busbar. Connect also any separate ground conductors or cables to cabinet PE
busbar.
- Connect the phase conductors to the input power terminals. Depending on the
connection principle see the appropriate connection diagram above.
- Tighten the phase conductors and PE to 70 Nm (50 lbf.ft) torque.
5. Refit the shroud removed earlier and close the door.
Incoming cubicle from front, Incoming cubicle from Lower part of the incoming cubicle from front,
door closed front, door open shroud removed
2
4
Electrical installation
87
PE
W2
V2
W1
V1
M
U2
U1 3~
PE
PE
W2
V2
U2
W1
V1
M
U1 3~
W2 PE
V2
U2
Electrical installation
88
WARNING! The cabling from all inverter modules to the motor must be physically
identical considering cable type, cross-sectional area, and length.
PE
W2
V2
U2
W1
V1
M
U1 3~
W2 PE
V2
U2
Electrical installation
89
Connection procedure
WARNING! Read and follow the instructions given in chapter Safety instructions.
Ignoring the instructions can cause physical injury or death, or damage to the
equipment.
1. Open the door of the inverter module cubicle: Unlock the handle, release it from
the holder and turn upwards to release the door locking mechanism.
2. Remove the shroud that protect the output busbars and cable entries.
3. Unplug the socket of the cooling fan and remove the cooling fan. See Replacing
the fan in the inverter module cubicle (frame size R8i) on page 113.
4. Lead the cables into the inside of the cubicle. For minimum radio frequency
interference and motor bearing current, ground the cable shield 360° at the lead-
through.
5. Connect the cables as follows:
- Cut the cables to suitable length. Strip the cables and conductors. Fasten the
cable lugs to the conductor ends.
- Twist the cable shields into bundles and connect to cabinet ground busbar.
- Connect the phase conductors to the output terminals. See the appropriate
connection diagram above.
- Tighten the phase conductors and PE to 70 Nm (50 lbf.ft) torque.
6. Plug in the fan power supply and refit the fan.
7. Refit the shroud removed earlier and close the door.
8. Connect the motor end of the cable. See the diagrams above. For minimum radio
frequency interference and motor bearing current ground the cable shield 360° at
the lead-through of the motor terminal box, or ground the cable by twisting the
shield as follows: flattened width > 1/5 × length. For the motor specific
instructions, see the manufacturer’s user manual.
Electrical installation
90
Inverter module cubicle from Inverter module cubicle from Lower part of the inverter module cubicle from front,
front, door closed front, door open shroud removed
Terminals are
5
behind the fan.
1
3 3
360° grounding of the cable shield Alternative cable shield grounding means at the
at the inverter end motor end
8
4
Alternative 1:
360° grounding of the shield
Conductive gasket
b
a
Electrical installation
91
Connection diagram
Connect the motor cables directly to the output busbars of the inverter modules.
However, as there are bridging busbars between the inverter module outputs, it is
possible to arrange the cables asymmetrically between the modules. E.g. In case of
two parallel inverter modules it is possible to use three parallel cables to supply the
motor. See the diagram below. The bridging balances the motor current between the
modules.
PE
W2
V2
U2
WARNING! The bridging can carry the nominal output current of one inverter module. In case of three
parallel modules, ensure that the load capacity of the bridging is not exceeded. I.e. if the cabling
connects to the output busbars of one module only, use the module in the middle.
Notes:
Always use identical symmetric three phase cables. For selection of the motor cables, see chapter
Selecting the power cables on page 64.
Pay special attention to the grounding of the cable. 360° earthing is to be used at cable entries both at
the inverter end and at the motor end.
For the power cable terminal sizes and cabinet lead-through sizes, see section Units without the
Common Motor Terminal cubicle (no option +H359) on page 152.
For the power cable terminal tightening torques, see section Connection procedure on page 89.
Connection procedure
See Connection procedure on page 89.
Electrical installation
92
Connection diagram
PE
W2
V2
W1
V1
M
U2
U1 3~
PE
Electrical installation
93
Connection procedure
WARNING! Before start, read and follow the instructions given in chapter Safety
instructions. Ignoring the instructions can cause physical injury or death, or damage
to the equipment.
3 6 360° grounding
Conductive gasket
Electrical installation
94
L1
L2
L3
Option selections
+G344 Auxiliary transformers = Yes
+G307 Terminals for external = Yes
control voltage (UPS)
PE
L
1
2
Q12
1
2
Q11
>
>
L N
L N
Power supply for control circuitry Power supply for fans
Note:
Connect the external auxiliary power supply for control circuitry to Q11. Breakers Q11 and Q12 are
located in the diode supply cubicle.
Electrical installation
95
L N PE
1
2
1
2
3
Q11 Q12
Option selections
+G344 Auxiliary transformers = No
> > +G307 Terminals for external = No
control voltage (UPS)
Note:
Connect the external auxiliary power supply (control circuitry and fans) to Q11. Breakers Q11 and
Q12 are located in the diode supply cubicle.
L N PE L N PE
1
2
1
2
Q11 Q12
Option selections
+G344 Auxiliary transformers = No
+G307 Terminals for external = Yes
> > control voltage (UPS)
Note:
Connect the external auxiliary power supply to Q11 (control circuitry) and Q12 (fans). Breakers Q11
and Q12 are located in the diode supply cubicle.
Electrical installation
96
Electrical installation
97
Electrical installation
98
Electrical installation
99
Connections of main breaker/ See the circuit diagrams delivered with the unit for the terminal designations.
contactor control and supervision See Control cable connection procedure on page 100 for the cabling
circuits (no option +F255 or +F250) instructions.
Note: The terminal blocks for the user connections are located near the cable
entry of the supply unit cubicle.
Connection of external emergency Wire the external buttons in series with the cabinet-installed emergency stop
stop buttons button. See the circuit diagrams delivered with the drive.
See Control cable connection procedure below for the cabling instructions.
Note: The terminal blocks for the user connections are located near the cable
entry of the supply unit cubicle.
Connection to fieldbus adapter See the option module specific manual delivered with the drive for the
module connection terminals.
See Control cable connection procedure below and Installation of optional
modules and PC on page 101 for the cabling details.
Note: The option modules are attached to the RDCU unit which is located in
the swing out frame.
Connection of PC Connect the PC via a fibre optic link to RDCO board CH3.
See Control cable connection procedure below for the cabling details.
Note: RDCO is attached to the RDCU unit which is located in the swing-out
frame.
Connection of hardware option See the circuit diagrams delivered with the unit.
Electrical installation
100
Side view
Strain relief EMI conductive
cushions
If the outer surface of a cable shield is non-conductive, turn the shield inside out as shown below and
apply copper foil to keep the shielding continuous. Do not cut the grounding wire (if present).
Copper foil
Grounding wire
On top entry units, sort the cables so that the thinnest and thickest cables are at opposite ends of the
opening.
Top view
Electrical installation
101
Run the cables to the appropriate terminals. Wherever possible, use the existing cable trunking in the
cabinet. Use sleeving wherever the cables are laid against sharp edges.
Note: When running cables to the swing-out frame, leave some slack in the cable at the hinge to allow the
frame to open fully. Tie the cables to the cable supports wherever necessary.
Cut the cables to suitable length. Strip the cables and conductors.
Twist the cable shields into bundles and connect them to the ground terminal nearest to the terminal block.
Keep the unshielded portion of the cables as short as possible.
Connect the conductors to appropriate terminals (see External control connections to the inverter unit on
page 96 and the circuit diagrams delivered with the unit).
Refit any shrouds removed earlier. Close the cabinet door(s).
PC connection
WARNING! Read and follow the instructions given in chapter Safety instructions.
Ignoring the instructions can cause physical injury or death, or damage to the
equipment.
Connect PC to CH3 of RDCO board via a fibre optic link. RDCO is attached to an
option slot of the RDCU unit. See also Fibre optic links below.
WARNING! Read and follow the instructions given in chapter Safety instructions.
Ignoring the instructions can cause physical injury or death, or damage to the
equipment.
Insert optional modules (such as fieldbus adapters, I/O extension modules and pulse
encoder interfaces) into the optional module slots of the RDCU unit and secure with
two screws. The slots on the RDCU unit are described in Inverter unit control
interfaces on page 36. See also the appropriate optional module manual for
information on the cable connections.
Electrical installation
102
Module
Keep unshielded portion as
short as possible
Shield
1
2
3
4
To nearest PE terminal
CHASSIS
RTAC-01
PULSE ENCODER INTERFACE
GND
Note 1: If the encoder is of unisolated
12345678 123456
SHLD
F01
type, ground the encoder cable at the
CDE
23 6
SHLD
45
AB
789
CHA
CHB
CHA-
X2
Keep unshielded portion as
WD/
CHB-
NODE ID
0V
encoder cable shield at the drive and
the encoder end.
1
2
3
4
VOUT
+15V
X1
VIN
+24V
Note 2: Twist the pair cable wires.
Electrical installation
103
Installation checklist
Installation checklist
Check the mechanical and electrical installation of the drive before start-up. Go
through the checklist below together with another person.
WARNING! Read and follow the instructions given in Safety instructions. Ignoring
the instructions can cause physical injury or death, or damage to the equipment.
Check…
MECHANICAL INSTALLATION
The ambient operating conditions are within the allowed limits. See chapter Technical data.
The unit has been fixed properly to floor, and if necessary (e.g. marine application) also to the wall.
ELECTRICAL INSTALLATION See chapters Planning the electrical installation, Electrical installation.
The motor and the driven equipment are ready for start.
The supply (input power) voltage matches the nominal input voltage of the drive.
There are no tools, foreign objects or dust from drilling inside the drive.
Supply (input power) voltage cannot be connected to the output of the drive (with a bypass connection).
For drives with Category 1 Emergency stop function (option +Q952): The time relay has been set to a suitable
value (e.g. somewhat longer than the stop ramp of the inverter units).
The cooling circuit joints at the shipping split joining cubicles are tight.
Installation checklist
104
Installation checklist
105
Start-up
Start-up
106
Start-up
107
Fault tracing
Fault tracing
108
Fault tracing
109
Maintenance
Maintenance intervals
If installed in an appropriate environment, the drive requires very little maintenance.
This table lists the routine maintenance intervals recommended by ABB.
Every 6 years Change of fans See section Cooling fans on page 110.
PPCS branching unit Locate the APBU unit. Switch off the power to
Every 6 years (APBU-xx) – Memory the unit. Remove cover. Replace battery with a
backup battery renewal new CR 2032 battery.
Note: If the drive is equipped with the cooling unit (option +C140 or +C141), see
also the maintenance intervals given in ACS800-1007LC User’s Manual
(3AFE68621101 [English]).
Maintenance
110
Cooling fans
WARNING! Read and follow the instructions in chapter Safety instructions. Ignoring
the instructions can cause physical injury or death, or damage to the equipment.
1. Ensure that the drive is disconnected from the power line and all other
precautions described in section Installation and maintenance work on page 6 of
chapter Safety instructions have been taken into consideration.
2. Open the door and remove the lower shroud of the cubicle.
3. Units with charging resistors (without option +A018): Remove the four
mounting screws of the charging unit and pull the unit slightly outwards.
4. Units with charging resistors (without option +A018): Unplug the two wire
sets connecting the charging unit to the converter module.
5. Units with charging resistors (without option +A018): Unplug the wire set
connecting the charging unit to terminal block at the lower part of the cubicle.
6. Units with charging resistors (without option +A018): Remove the charging
unit.
7. Unplug the fan power supply.
8. Remove the six screws that connect the fan frame to the cubicle and pull the
frame out of the cubicle.
9. Remove the four screws that fasten the fan to the fan frame.
10. Install a new fan in reverse order.
3
4
5
8
9
7
Maintenance
111
WARNING! Read and follow the instructions in chapter Safety instructions. Ignoring
the instructions can cause physical injury or death, or damage to the equipment.
1. Ensure that the drive is disconnected from the power line and all other
precautions described in Installation and maintenance work on page 6 of
chapter Safety instructions have been taken into consideration.
2. Open the door and remove the shroud to gain access to the fan.
3. Remove the four mounting screws of the fan.
4. Unfasten the power supply cable of the fan and pull the fan out of the cubicle.
5. Remove the four screws that fasten the fan and the fan grille.
6. Install a new fan in reverse order.
Maintenance
112
WARNING! Read and follow the instructions in chapter Safety instructions. Ignoring
the instructions can cause physical injury or death, or damage to the equipment.
1. Ensure that the drive is disconnected from the power line and all other
precautions described in Installation and maintenance work on page 6 of
chapter Safety instructions have been taken into consideration.
2. Open the door and remove the shroud to gain access to the fan.
3. Remove the four mounting screws of the fan.
4. Unfasten the power supply cable of the fan and pull the fan out of the cubicle.
5. Remove the four screws that fasten the fan and the fan grille.
6. Install a new fan in reverse order.
5
5 3
Maintenance
113
Replacing the fan in the inverter module cubicle (frame size R8i)
WARNING! Read and follow the instructions in chapter Safety instructions. Ignoring
the instructions can cause physical injury or death, or damage to the equipment.
1. Ensure that the drive is disconnected from the power line and all other
precautions described in Installation and maintenance work on page 6 of
chapter Safety instructions have been taken into consideration.
2. Open the door and remove the shroud to gain access to the fan.
3. Remove the two screws that fasten the fan collar to the cabinet frame.
4. Unplug the power supply cable of the fan and slide the fan and the collar out of
the cubicle.
5. Remove the two screws that fasten the fan to the support plate at front.
6. Remove the four screws that fasten the fan output flange to the fan collar.
7. Install a new fan in reverse order.
Maintenance
114
WARNING! Read and follow the instructions in chapter Safety instructions. Ignoring
the instructions can cause physical injury or death, or damage to the equipment.
1. Ensure that the drive is disconnected from the power line and that all other
precautions described in Installation and maintenance work on page 6 of
chapter Safety instructions have been taken into consideration.
2. Remove the shrouds: metal grating at the lower part of the cubicle (four screws),
and two plastic shrouds, one at the upper part of the cubicle and one at the
middle (four screws each). Remove also the supports of the upper shroud. Mark
down the position and facing of the supports!
3. Close the inlet (a) and outlet (b) valves of the cubicle, and drain the cooling
circuit (see Draining the internal cooling circuit on page 132. Note: Drain (d) and
bleed (c) valves have locking handles. Release the mechanism before turning.
4. Remove the fan. See Replacing the fan of the diode supply module cubicle on
page 110.
5. Unplug the connector that connects to the bottom of the module. First loosen the
two screws that fasten the connector to its counterpart (3 mm slotted head).
6. Remove the AC fuses: Loosen the screws on both sides and pull the fuses off.
7. Remove the four bolts that fasten the bottom of the module to the cabinet
support frame: two to back and two to sides of the cubicle.
8. Fasten the right-hand side support of the winch to the support frame of the
cubicle (four screws). Fasten the left-hand side support of the winch to the
support frame of the cubicle (four screws). Note: Position the guide pins of the
supports in the holes of the cabinet frame before tightening the screws. For
detailed instructions, see Installing the winch on page 124.
Maintenance
115
2 Removing the shrouds 3 Draining the cooling circuit 4 Removing the fan 5 Unplugging the connector
b c
a d
6 Removing the AC fuses 7 Removing the lower mounting 8 Fastening the supports of the winch
screws
Maintenance
116
9. Open the swing-out frame: two screws on the left, two on the right.
10. Open the locking of auxiliary hinge of the swing out-frame to allow the frame to
open fully: one screw at top, one at bottom.
11. Decouple the cooling circuit inlet pipes from the module (two connectors on
bottom plate of the module): Unscrew the locking nut until fully open and pull the
pipe out.
12. Decouple the cooling circuit outlet pipes from the module (two connectors on
front plate of the module): Unscrew the locking nut until fully open and pull the
pipe out.
13. Assemble the module installation stand. See Installing the installation stand for
supply module D3 and D4 replacement on page 125. Pay attention to the width:
Select the right braces to match the width of the stand to the width of the cubicle.
14. Fasten the module installation stand to the frame of the cubicle (2 × 5 screws).
Align the stand and the rails in the cubicle on which the module lies. Adjust the
height of the feet. Note: Remove the cabinet hinge first if necessary.
WARNING! The feet must lean on a solid floor. The cubicle may topple over when
the heavy module is pulled out if the stand is not supported properly.
15. Disconnect the output busbars of the module: four busbars, one screw per
busbar.
Maintenance
117
9 Opening the swing-out 10 Opening the locking 11 Decoupling the inlet 12 Decoupling the outlet
frame
13 Assembling the stand 14 Fastening the stand 15 Disconnecting the output busbars
Maintenance
118
16. Remove the two screws that fasten the top of the module to the back of the
cabinet.
17. Install the winch: Lead the crossbeam through the left and right winch support
and the winch body. Lock the crossbeam with two locking pins.
18. Pull the module out of the cubicle onto the installation stand. Keep the pipes and
wires away from sharp edges.
WARNING! Before fastening the lifting bar, always ensure that the lifting cable is
tightly wound on the drum of the winch. A slack cable may slip, making the lifting of a
heavy module unstable. A swinging or falling module may cause damage, injury or
even death. See chapter Safety instructions for more detailed information on safe
use of the winch.
19. Fasten the lifting bar of the winch to the two module lifting holes.
20. Winch the module up.
21. Remove the module installation stand.
22. Winch the module down and lay it on a pallet.
WARNING! The module is heavy and its centre of gravity is high. The module
topples over easily. Never manoeuvre it in upright position untied. It is highly
recommended to lay the module on its side before moving the pallet.
Maintenance
119
16 Removing the screws 17 Installing the winch 18 Pulling the module out
19 Fastening the lifting bar Winching the Removing the Winching the
20 21 22
module up stand module down
Maintenance
120
WARNING! Read and follow the instructions in chapter Safety instructions. Ignoring
the instructions can cause physical injury or death, or damage to the equipment.
1. Ensure that the drive is disconnected from the power line and all other
precautions described in Installation and maintenance work on page 6 of
chapter Safety instructions have been taken into consideration.
2. Remove the shrouds: metal grating at the upper and lower part of the cubicle
(four screws each).
3. Close the inlet (a) and outlet (b) valves of the cubicle, and drain the cooling
circuit (see Draining the internal cooling circuit on page 132. Note: Drain (d) and
bleed (c) valves have locking handles. Release the mechanism before turning.
4. Fasten the right-hand side support of the winch to the support frame of the
cubicle (four bolts). Fasten the left-hand side support of the winch to the support
frame of the cubicle (four bolts). Note: Position the guide pins of the supports in
the holes of the cabinet frame before tightening the bolts. For detailed
instructions see Installing the winch on page 124.
5. Install the winch: Lead the crossbeam through the left and right winch support
and the winch body. Lock the crossbeam with two locking pins (a).
6. Open the swing out frame: two screws on the left-hand side, two on the right.
7. Open the locking of the auxiliary hinge of the swing out frame to allow the frame
to open fully: one screw on top (a), one on bottom (b).
8. Decouple the cooling circuit inlet pipe from the module: Unscrew the locking nut
until fully open and pull the pipe out.
9. Decouple the cooling circuit outlet pipe from the module: Unscrew the locking
nut until fully open and pull the pipe out.
Maintenance
121
2 Removing the shrouds 3 Draining the cooling unit 4 Fastening the supports of the winch
c
b
a d
6 Opening the swing- 7 Opening the locking 8 9 Decoupling the inlet (8) and outlet (9)
out frame
Maintenance
122
WARNING! The feet must lean on a solid floor. The cubicle may topple over when
the heavy module is pulled out if the stand is not supported properly.
16. Fasten the lifting bar of the winch to the two module lifting holes.
WARNING! Before fastening the lifting bar, always ensure that the lifting cable is
tightly wound on the drum of the winch. A slack cable may slip, making the lifting of a
heavy module unstable. A swinging or falling module may cause damage, injury or
even death. See chapter Safety instructions for more detailed information on safe
use of the winch.
17. Pull the module out of cubicle onto the installation stand. Keep the pipes and
wires away from the sharp edges.
18. Winch the module up.
19. Remove the module installation stand.
20. Winch the module down and lay it on a pallet.
WARNING! The module is heavy and its centre of gravity is high. The module
topples over easily. Never manoeuvre it in upright position untied. It is highly
recommended to lay the module on its side before moving the pallet.
Maintenance
123
10 Unplugging the fibre optic 13 Disconnecting the 14 Fastening the 15 Pulling the module out
cables DC busbars installation stand
12 12
12
12
11
10
12 12
16 Fastening the lifting 17 Winching the module 18 Removing the 19 Winching the module
bar up installation stand down
Maintenance
124
WARNING! Before fastening the lifting bar to the module, always ensure that the
lifting cable is tightly wound on the drum of the winch. A slack cable may slip, making
the lifting of a heavy module unstable. A swinging or falling module may cause
damage, injury or even death. See chapter Safety instructions for detailed
information on safe use of the winch.
1 2
Do not overtighten!
Max.torque 5.5 Nm.
Ensure that the studs
are in frame holes
when tightening the
screws.
Maintenance
125
WARNING! The feet must lean on a solid floor. The cubicle may topple over when
the heavy module is pulled out if the stand is not supported properly.
Slide
Brace
Do not overtighten!
Max.torque 5.5 Nm.
Ensure that the pins
are in frame holes
when tightening the
screws.
Maintenance
126
WARNING! The feet must lean on a solid floor. The cubicle may topple over when
the heavy module is pulled out if the stand is not supported properly.
Maintenance
127
Capacitors
The inverter modules employ several electrolytic capacitors. Their life span is at
least 90 000 hours depending on the operating time of the drive, loading and
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.
Reforming
Reform (re-age) spare part capacitors once a year according to ACS 600/800
Capacitor Reforming Guide (code: 64059629 [English]), available through your local
ABB representative.
Capacitor replacement
Contact an ABB service representative.
Maintenance
128
Maintenance
129
General
The cooling system of an ACS800 liquid-cooled drive consists of two circuits: firstly,
the internal cooling circuit that covers the heat-generating electrical components and
transfers the heat to the cooling unit, and the external cooling circuit that is usually
part of a larger external cooling system. This chapter deals with the internal cooling
circuit.
b d b d b d b d Coolant
OUT
A/L
Coolant
IN
a c a c a c a c
The modules in each cubicle can be isolated from the main cooling circuit by closing
the inlet (a) and outlet valves (b). Each cubicle is also equipped with a drain valve (c)
and a bleed valve (d).
Return
Heat
exchanger
Internal circuit External circuit
Bypass valve
Infeed
TC
Installation
Connect the external cooling circuit directly to the coupling flanges on the side of the
drive. Lay liquid piping with extreme care. Secure the pipes properly mechanically
and check for leaks.
WARNING! Bleeding of the cooling circuit is very important and has to be done with
great care. Air bubbles in the cooling circuit may reduce or completely block coolant
flow and lead to overheating. Let the air out of the cooling system while filling in
coolant and, e.g. after any power module replacements.
1. Lead the bleed hoses into buckets or other suitable containers. Extend the
standard hoses when necessary.
Note: Draining propylene glycol into the sewer system is not allowed.
Note: Draining propylene glycol into the sewer system is not allowed.
1. Lead the bleed and drain hoses into buckets or other suitable containers. Extend
the standard hoses when necessary.
2. Open the bleed valves to let air displace the liquid.
3. If required, dry the piping with compressed oil-free air of less than 6 bar.
4. If the drive is to be stored in temperatures below 0°C (32°F),
• fill the cooling circuit with a mixture of water, corrosion inhibitor and DOW
Propylene Glycol according to Freeze protection and corrosion inhibition below.
• drain the cooling circuit.
Specifications
Temperature limits
Ambient temperature: See chapter Technical data.
Minimum coolant inlet temperature: Condensation is not allowed. The minimum
coolant temperature to avoid condensation (at an atmospheric pressure of 1 bar) is
shown below as a function of the relative humidity (φ) and the ambient
temperature (Tair).
Tair Min. Tcoolant (°C)
(°C) φ = 95% φ = 80% φ = 65% φ = 50% φ = 40%
5 4.3 1.9 -0.9 -4.5 -7.4
10 9.2 6.7 3.7 -0.1 -3.0
15 14.2 11.5 8.4 4.6 1.5
20 19.2 16.5 13.2 9.4 6.0
25 24.1 21.4 17.9 13.8 10.5
30 29.1 26.2 22.7 18.4 15.0
35 34.1 31.1 27.4 23.0 19.4
40 39.0 35.9 32.2 27.6 23.8
45 44.0 40.8 36.8 32.1 28.2
50 49.0 45.6 41.6 36.7 32.8
55 53.9 50.4 46.3 42.2 37.1
Pressure limits
Base pressure: 100…150 kPa (recommended); 200 kPa (maximum). “Base
pressure” denotes the pressure of the system compared with the atmospheric
pressure when the cooling circuit is filled with coolant
Air counterpressure in the expansion tank: 40 kPa
Maximum design pressure: 600 kPa
Minimum pressure difference: 100 kPa / 120 kPa (hydrostatic)
Maximum pressure difference: 250 kPa
Water quality
Tap water
The use of tap water is allowed as follows. Tap water must fulfil the requirements of
the Council Directive 98/83/EC of 3/11/98 on the quality of water intended for human
consumption. Corrosion inhibition with 0.5% by volume Cortec VCI-649 is required.
pH value 6 to 9
Chloride < 50 mg/l
Sulphate < 100 mg/l
Total dissolved solids < 200 mg/l, no deposits are allowed at
the temperature of +57°C
Total hardness as CaCO3 < 250 mg/l
Conductivity < 400 µS/cm (this equals the resistance
of > 2500 ohm/cm)
The water must be clean of solid matter.
Glycol concentration
This graph shows the required glycol concentration in weight percentage according
to ambient/storage temperature T.
80
60
40
20
0 T (°C)
-50 -40 -30 -20 -10 0 +5
WARNING! Operation at temperatures below 0°C (32°F) is not permitted even with
antifreeze.
Note: If more than 25% or DOW Propylene Glycol is added, the pressure loss in the
system increases. An operating pressure of more than 150 kPa is required for
sufficient flow.
Materials
Materials used in the internal cooling circuit are:
• stainless steel AISI 316L (UNS 31603)
• heavy gauge aluminium
• plastic materials such as PA, PEX and Teflon
Note: PVC hoses are not suitable for use with antifreeze.
• rubber gasket NBR (nitrile rubber).
WARNING! If connecting external piping to the internal cooling circuit, use only
materials that are specified above. Copper and brass must not be used under any
circumstances. Even minor dissolution of copper can cause copper precipitation on
aluminium and subsequent galvanic corrosion. The liquid cooling system may not
contain any zinc (e.g. galvanized pipes) at all since zinc would react with the
inhibitor.
If the plant incorporates normal iron pipes or cast iron accessories (e.g. motor
housings), a liquid cooling unit with a heat exchanger (such as the ACS800-1007LC)
must be used to separate the systems.
Analogue outputs
Two programmable current outputs: 0 (4) to 20 mA, RL < 700 ohm
Resolution 0.1% (10 bit)
Inaccuracy ± 1% (Full Scale Range) at 25 °C (77°F). Temperature coefficient: ± 200 ppm/°C
(± 111 ppm/°F) max.
Digital inputs
With Standard Application Program six programmable digital inputs (common ground:
24 VDC, -15% to +20%) and a start interlock input. Group isolated, can be divided in
two isolated groups (see Isolation and grounding diagram below).
Thermistor input: 5 mA, < 1.5 kohm “1” (normal temperature), > 4 kohm “0” (high
temperature), open circuit “0” (high temperature).
Internal supply for digital inputs (+24 VDC): short-circuit proof. An external 24 VDC
supply can be used instead of the internal supply.
Isolation test voltage 500 VAC, 1 min.
Logical thresholds < 8 VDC “0”, > 12 VDC “1”
Input current DI1 to DI 5: 10 mA, DI6: 5 mA
Filtering time constant 1 ms
Relay outputs
Three programmable relay outputs
Switching capacity 8 A at 24 VDC or 250 VAC, 0.4 A at 120 VDC
Minimum continuous current 5 mA rms at 24 VDC
Maximum continuous current 2 A rms
Isolation test voltage 4 kV AC, 1 minute
The terminals on the RMIO board as well as on the optional modules attachable to the board fulfil the Protective Extra Low
Voltage (PELV) requirements stated in EN 50178 provided that the external circuits connected to the terminals also fulfil the
requirements and the installation site is below 2000 m (6562 ft). Above 2000 m (6562 ft), consult an ABB representative.
9 AO1+
10 AO1-
11 AO2+
12 AO2-
X22
1 DI1
2 DI2
3 DI3
4 DI4
Jumper J1 settings:
9 DGND1
Technical data
Ratings
The ratings with 50 Hz and 60 Hz supplies are given below.
Drive type Nominal ratings No-overload Light-overload use Heavy-duty use
use
Icont.max Imax Pcontmax I2N PN I2hd Phd
A (AC) A kW A kW A kW
UN = 400 V
ACS800-07LC-0390-3 563 674 315 540 250 421 200
ACS800-07LC-0470-3 678 837 355 651 355 507 250
ACS800-07LC-0620-3 889 1037 500 853 355 665 355
ACS800-07LC-0760-3 1103 1279 630 1059 560 825 450
ACS800-07LC-0920-3 1329 1590 710 1276 710 994 500
ACS800-07LC-1210-3 1742 1994 900 1673 900 1303 710
ACS800-07LC-1370-3 1973 2347 1120 1894 1120 1476 900
ACS800-07LC-1790-3 2587 2941 1400 2484 1400 1935 1120
ACS800-07LC-2370-3 3414 3906 2000 3277 2000 2553 1400
ACS800-07LC-2940-3 4245 4858 2500 4075 2240 3175 1800
ACS800-07LC-3510-3 5067 5799 2800 4865 2800 3790 2000
UN = 500 V
ACS800-07LC-0470-5 546 673 355 524 355 408 250
ACS800-07LC-0550-5 630 838 400 605 400 471 315
ACS800-07LC-0730-5 840 1042 560 806 560 628 400
ACS800-07LC-0930-5 1070 1280 710 1027 710 800 560
ACS800-07LC-1070-5 1235 1589 900 1185 710 924 630
ACS800-07LC-1430-5 1646 1996 1120 1581 1120 1232 710
ACS800-07LC-1590-5 1833 2344 1250 1760 1250 1371 900
ACS800-07LC-2120-5 2444 2943 1600 2347 1600 1828 1250
ACS800-07LC-2790-5 3226 3885 2240 3097 2240 2413 1600
ACS800-07LC-3470-5 4011 4830 2800 3851 2800 3000 2000
ACS800-07LC-4150-5 4788 5801 3360 4596 3200 3581 2500
UN = 690 V
ACS800-07LC-0700-7 583 872 560 560 500 436 400
ACS800-07LC-0940-7 790 1182 710 759 710 591 560
ACS800-07LC-1070-7 898 1344 900 863 710 672 630
ACS800-07LC-1370-7 1143 1710 1120 1097 900 855 710
ACS800-07LC-1590-7 1334 1996 1250 1281 1250 998 900
ACS800-07LC-2030-7 1697 2538 1600 1629 1600 1269 1250
ACS800-07LC-2680-7 2239 3350 2240 2150 2000 1675 1600
ACS800-07LC-3330-7 2785 4166 2800 2673 2500 2083 2000
ACS800-07LC-3970-7 3324 4974 3200 3191 3200 2487 2500
ACS800-07LC-4630-7 3878 5802 3750 3723 3600 2901 2800
ACS800-07LC-5300-7 4432 6630 4480 4255 4200 3315 3200
ACS800-07LC-5960-7 4986 7460 5000 4787 4800 3730 3600
ACS800-07LC-6620-7 5540 8288 5600 5319 5300 4144 4200
PDM-00430970-A.6
Technical data
142
Symbols
Nominal ratings
Icont.max Continuous RMS output current. No overloadability at 40°C.
Imax Maximum output current. Allowable for 10 seconds at start, otherwise as long as allowed by drive
temperature.
Typical ratings for no-overload use
Pcont.max Typical motor power. The power ratings apply to most IEC 34 motors at nominal voltage 690 V.
Typical ratings for light-overload use (10% overloadability)
I2N Continuous rms current. 10% overload is allowed for 1 minute every 5 minutes.
PN Typical motor power. The power ratings apply to most IEC 34 motors at nominal voltage 690 V.
Typical ratings for heavy-duty use (50% overloadability)
I2hd Continuous rms current. 50% overload is allowed for 1 minute every 5 minutes.
Phd Typical motor power. The power ratings apply to most IEC 34 motors at nominal voltage 690 V.
Derating
The load capacity (current and power) decreases if the installation site altitude exceeds 1000 metres
(3281 ft), or if the ambient temperature exceeds 45 °C (104 °F).
Temperature derating
In the ambient temperature range +45°C (+113°F) to +55°C (+131°F), the rated output current is
decreased by 1% for every additional 1°C (1.8°F). The output current is calculated by multiplying the
current given in the rating table by the derating factor.
Example If the ambient temperature is 50°C (+122°F), the derating factor is 100% - 1 % · 5°C = 95%
or 0.95. The output current is then 0.95 × I or 0.95 × I . °C
2N cont.max
Altitude derating
At altitudes from 1000 to 4000 m (3281 to 13123 ft) above sea level, the derating is 0.5% for every
100 m (328 ft). For a more accurate derating, use the DriveSize PC tool.
Output frequency derating
At frequencies over 200 Hz, the derating is 0.5% for every additional 1 Hz.
Technical data
143
2)
Fan of diode supply module (Y40.1) 1.3 1.6 3.2
3)
Main breaker/contactor control circuit 1.0 1.0 2.0
-
Control relays 0.5 0.5 1.0
4)
Fan in auxiliary control cubicle (Y1) 0.4 0.4 0.8
5)
Fan in incoming cubicle (Y11.1…Y14.1) 0.4 0.4 0.8
Inverter unit and options
-
24 VDC power supply (U10), and control relays 1.3 1.3 2.5
2)
Fan of inverter module (Y41.1) 0.8 1.0 2.0
Prevention of unexpected start-up circuit 0.4 0.4 0.8 6)
Brake unit
7)
Fan of chopper NBRA-658 (or -659 or -669) 0.4 0.5 1.0
8)
Fan of resistor unit 2×SAFUR200F500 2.8 3.4 6.8
Cooling unit
24 VDC power supply, and control relays See ACS800-1007LC User’s Manual
(3AFE68621101 [English]).
Notes:
1) Only with option +G304 (115 VAC control voltage)
2) There is one fan per supply or inverter module.
3) There is one control circuit per breaker (or contactor). Six-pulse supply unit has one breaker, twelve-pulse unit two, etc.
Note that the drive always supplies the breaker control circuit despite of the location of the breaker.
4) Only with option +G344.
5) Only with option +F255 or +F250. There is one fan in 400 mm wide cubicle, two fans in 600 mm and 1000 mm cubicles.
6) Only with option +Q950.
7) Only with option +D150. Number of choppers is visible in the type code, e.g. +2D150 = 2 choppers.
8) Only with option +D151. Number of choppers also define the number of resistor units. There is one resistor unit
(2×SAFUR200F500 resistors) per chopper.
Technical data
144
Technical data
145
Technical data
146
Technical data
147
Technical data
148
Diode Supply Unit type Basic DSU module type AC fuses DC fuses
Frame Type Code1) Qty Type Code1) Qty
ACS800-307LC-2540-7 ACS800-704LC-1370-7 2×D4 170M6263 68653215 12 170M5496 68653240 16
ACS800-307LC-3820-7 ACS800-704LC-2150-7 2×D4 170M6267 68636540 12 170M5499 68636531 16
ACS800-307LC-5980-7 ACS800-704LC-2150-7 3×D4 170M6267 68636540 18 170M5499 68636531 24
12-pulse diode supply
ACS800-507LC-1370-7 ACS800-704LC-1370-7 D4 170M6263 68653215 6 170M5496 68653240 8
ACS800-507LC-2150-7 ACS800-704LC-2150-7 D4 170M6267 68636540 6 170M5499 68636531 8
ACS800-507LC-2540-7 ACS800-704LC-1370-7 2×D4 170M6263 68653215 12 170M5496 68653240 16
ACS800-507LC-3820-7 ACS800-704LC-2150-7 2×D4 170M6267 68636540 12 170M5499 68636531 16
ACS800-507LC-5980-7 ACS800-704LC-2150-7 3×D4 170M6267 68636540 18 170M5499 68636531 24
18-pulse diode (supply)
ACS800-1107LC-1910-7 ACS800-304LC-0680-7 + D3+ 170M6263 68653215 9 170M5496 68653240 12
ACS800-704LC-1370-7 D4
ACS800-1107LC-2990-7 ACS800-304LC-1070-7 + D3+ 170M6267 68636540 9 170M5499 68636531 12
ACS800-704LC-2150-7 D4
ACS800-1107LC-3810-7 ACS800-704LC-1370-7 3×D4 170M6263 68653215 18 170M5496 68653240 24
ACS800-1107LC-5980-7 ACS800-704LC-2150-7 3×D4 170M6267 68636540 18 170M5499 68636531 24
24-pulse diode supply
ACS800-1207LC-2540-7 ACS800-704LC-1370-7 2×D4 170M6263 68653215 12 170M5496 68653240 16
ACS800-1207LC-3820-7 ACS800-704LC-2150-7 2×D4 170M6267 68636540 12 170M5499 68636531 16
PDM-00430970.xls-A.25
1)
ABB factory code
Technical data
149
Technical data
150
Units without built-in main breaker or contactor (no option +F250 or +F255)
The cables enter the supply module cubicle(s). Each supply module is installed in a
cubicle of its own.
1×D3 3 - 70 Nm 12 × Ø60 mm
M12 (½”)
1×D4 2×3 2×3 (50 lb.ft) (2.36“)
70 Nm 2 × (12 ×
2×D4 2×(2×3) 2×(2×3) M12 (½”)
(50 lb.ft) Ø60 mm)
70 Nm 3 × (12 ×
3×D4 3×(2×3) 3×(2×3) M12 (½”)
(50 lb.ft) Ø60 mm)
Dimensions of input
busbar in
supply module cubicle
Technical data
151
1×D3 2×31) -
18 × Ø60 mm
1×D4 2×31) 2×(2×3)1) M12 (½”) 70 Nm (50 lb.ft)
(2.36“)
2×D4 3×31) 2×(2×3)1)
2 × (18 ×
3×D4 2×(3×3)1) M12 (½") 70 Nm (50 lb.ft)
Ø60 mm)
3×32) M12 (½") 70 Nm (50 lb.ft) 27 × Ø60 mm
6 × Ø60 mm
Any 3 2×3 M12 (½") 70 Nm (50 lb.ft)
(2.36“)
Technical data
152
Units without the Common Motor Terminal cubicle (no option +H359)
When the drive is not equipped with the Common Motor Terminal (CMT) cubicle, the
motor cables enter the inverter module cubicle(s).
Inverter unit Tightening Cable lead-
No. of busbars Screw size
configuration torque throughs
n × [6 × Ø60 mm
n×R8i n×3 M12 (½”) 70 Nm (50 lb.ft)
(2.36“)]
Technical data
153
Units with the Common Motor Terminal (CMT) cubicle (option +H359)
Inverter unit
CMT cubicle No. of Tightening
ACS800-07LC Screw size Cable lead-throughs
Modules width [mm] busbars torque
type
R8i…2×R8i All 300 3
-1370-3, 1590-5, M12 (½”) 70 Nm (50 lb.ft) 9 × Ø60 mm (2.36“)
3×R8i 300 3
1590-7, 2030-7
3×R8i -1790-3, 2120-5 400 3
M12 (½”) 70 Nm (50 lb.ft) 12 × Ø60 mm
4×R8i, 5×R8i 690 V 400 3
4×R8i 400 and 500 V 600 2×3 M12 (½”) 70 Nm (50 lb.ft) 18 × Ø60 mm
5×R8i, 6×R8i 400 and 500 V 2×400 2×3 M12 (½”) 70 Nm (50 lb.ft) 2 × (12 × Ø60 mm)
6×R8i, 7×R8i 690 V 600 2×3 M12 (½”) 70 Nm (50 lb.ft) 18 × Ø60 mm
8×R8i, 9×R8i 690 V 2×400 2×3 M12 (½”) 70 Nm (50 lb.ft) 2 × (12 × Ø60 mm)
12 × Ø60 mm +
10×R8i 690 V 400+600 3+(2×3) M12 (½”) 70 Nm (50 lb.ft)
18 × Ø60 mm
Technical data
154
Technical data
155
Motor connection
Voltage (U2) 0 to U1, 3-phase symmetrical, Umax at the field weakening point
Frequency DTC mode: 0 to 3.2 × fFWP. Maximum frequency 300 Hz.
UNmains
fFWP = · fNmotor
UNmotor
where fFWP = frequency at field weakening point; UNmains = mains (input power) voltage;
UNmotor = rated motor voltage; fNmotor = rated motor frequency
Frequency resolution 0.01 Hz
Current See Ratings on page 141.
Power limit 2 × Phd. After approximately 2 minutes at 2 × Phd, the limit is set at Pcont.max.
Field weakening point 8 to 300 Hz
Switching frequency 2 kHz (average)
Motor cable lead-throughs Units without the Common Motor Terminal cubicle: TO BE ADDED
Units with the Common Motor Terminal cubicle: TO BE ADDED
Maximum recommended 100 m (328 ft). Motor cables up to 500 m (1640 ft) long are allowed but then the
motor cable length installation does not fulfil category C2 or C3 of the EMC product standard. See section CE
marking.
Efficiency
Approximately 98% at nominal power level
Cooling
Method Liquid cooling.
Degrees of protection
IP42; IP54
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 0 to 4000 m (13123 ft) above - -
sea level [above 1000 m
(3281 ft), see Derating on
page 142]
Air temperature 0…+55° (+32…+131°F) -40…+70°C (-40 to +158°F) -40…+70°C (-40 to +158°F)
[above +45°C (+113°F), see
Derating on page 142]
Relative humidity 5 to 95% Max. 95% Max. 95%
No condensation allowed. Maximum allowed relative humidity is 60% in the presence of
corrosive gases.
Contamination levels No conductive dust allowed.
(IEC60721-3-3, IEC60721-3-2, Boards with coating: Boards with coating: Boards with coating:
IEC60721-3-1) Chemical gases: Class 3C2 Chemical gases: Class 1C2 Chemical gases: Class 2C2
Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2
Atmospheric pressure 70 to 106 kPa 70 to 106 kPa 60 to 106 kPa
0.7 to 1.05 atmospheres 0.7 to 1.05 atmospheres 0.6 to 1.05 atmospheres
Technical data
156
IEC 60068-2-6
0,075 mm (0…58 Hz)
10 m/s2 (58…150Hz)
Max. amplification 10
Shock (IEC 60068-2-29) Not allowed Max. 100 m/s2 (330 ft./s2), Max. 100 m/s2 (330 ft./s2),
11 ms 11 ms
Free fall Not allowed 100 mm (4 in.) for weight 100 mm (4 in.) for weight
over 100 kg (220 lb.) over 100 kg (220 lb.)
Materials
Cabinet Hot-dip zinc-coated (thickness approx. 20 µm) steel sheet (thickness 1.5 mm) with
polyester thermosetting powder coating (thickness approx. 80 µm) on visible surfaces
except back panel. Colour: RAL 7035 (light beige, semigloss).
Busbars Tin- or silver-plated copper
Internal cooling circuit piping Aluminium, acid-fast stainless steel, PA pipes
Fire safety of materials Insulating materials and non-metallic items: Mostly self-extinctive
(IEC 60332-1)
Packaging Frame: Wood or plywood. Plastic wrapping: PE-LD. Bands: PP or steel.
Disposal The drive contains raw materials that should be recycled to preserve energy and natural
resources. The package materials are environmentally compatible and recyclable. All
metal parts can be recycled. The plastic parts can either be recycled or burned under
controlled circumstances, according to local regulations. Most recyclable parts are marked
with recycling marks.
If recycling is not feasible, all parts excluding electrolytic capacitors and printed circuit
boards can be landfilled. The DC capacitors (C1-1 to C1-x) contain electrolyte and the
printed circuit boards contain lead, both of which are classified as hazardous waste within
the 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.
Technical data
157
Applicable standards
The drive complies with the following standards.
• EN 50178 (1997) Electronic equipment for use in power installations.
• EN 60204-1 (1997) Safety of machinery. Electrical equipment of machines. Part 1: General requirements.
Provisions for compliance: The final assembler of the machine is responsible for installing
- an emergency-stop device
- a supply disconnecting device.
• EN 60529: 1991 (IEC 529) Degrees of protection provided by enclosures (IP code).
• IEC 60664-1 (1992) Insulation coordination for equipment within low-voltage systems. Part 1: Principles,
requirements and tests.
• EN 61800-3 (2004) EMC product standard including specific test methods
• EN 61800-5-1 Adjustable speed electrical power drive systems - Part 5-1: safety requirements
• UL 508A UL Standard for Safety, Power Conversion Equipment, second edition
• CSA C22.2 No. 14-95 Industrial control equipment
Technical data
158
CE marking
A CE mark is attached to the drive to verify that the unit follows the provisions of the
European Low Voltage and EMC Directives (Directive 73/23/EEC, as amended by
93/68/EEC and Directive 89/336/EEC, as amended by 93/68/EEC).
Technical data
159
WARNING! The drive may cause radio interference if used in a residential or domestic environment.
The user is required to take measures to prevent interference, in addition to the requirements for CE
compliance listed above, if necessary.
Neighbouring network
Static screen
Point of measurement
Equipment 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 chapter Planning the electrical installation.
4. The drive is installed according to the instructions given in chapter Electrical installation.
Technical data
160
Technical data
161
Free Free
Height Depth Width 1 space space on Weight
Drive type Frame
above 1) side 2)
[mm] [mm] [mm] [mm] [mm] kg
UN=400 V
ACS800-07LC-0390-3 1×D3+1×R8i 2003 644 730 400 270 700
ACS800-07LC-0470-3 1×D3+1×R8i 2003 644 730 400 270 700
ACS800-07LC-0620-3 1×D3+1×R8i 2003 644 730 400 270 700
ACS800-07LC-0760-3 1×D4+2×R8i 2003 644 930 400 270 870
ACS800-07LC-0920-3 1×D4+2×R8i 2003 644 930 400 270 870
ACS800-07LC-1210-3 1×D4+2×R8i 2003 644 930 400 270 870
ACS800-07LC-1370-3 2×D4+3×R8i 2003 644 1530 400 270 1040
ACS800-07LC-1790-3 2×D4+3×R8i 2003 644 1530 400 270 1440
ACS800-07LC-2370-3 2×D4+4×R8i 2003 644 1830 400 270 1660
ACS800-07LC-2940-3 3×D4+5×R8i 2003 644 2430 400 270 1910
ACS800-07LC-3510-3 3×D4+6×R8i 2003 644 2630 400 270 2080
UN=500 V
ACS800-07LC-0470-5 1×D3+1×R8i 2003 644 730 400 270 700
ACS800-07LC-0550-5 1×D3+1×R8i 2003 644 730 400 270 700
ACS800-07LC-0730-5 1×D3+1×R8i 2003 644 730 400 270 700
ACS800-07LC-0930-5 1×D4+2×R8i 2003 644 930 400 270 870
ACS800-07LC-1070-5 1×D4+2×R8i 2003 644 930 400 270 870
ACS800-07LC-1430-5 1×D4+2×R8i 2003 644 930 400 270 870
ACS800-07LC-1590-5 1×D4+3×R8i 2003 644 1130 400 270 1040
ACS800-07LC-2120-5 2×D4+3×R8i 2003 644 1530 400 270 1440
ACS800-07LC-2790-5 2×D4+4×R8i 2003 644 1830 400 270 1660
ACS800-07LC-3470-5 3×D4+5×R8i 2003 644 2430 400 270 1910
ACS800-07LC-4150-5 3×D4+6×R8i 2003 644 2630 400 270 1080
UN=690 V
ACS800-07LC-0700-7 1×D3+1×R8i 2003 644 730 400 270 700
ACS800-07LC-0940-7 1×D3+2×R8i 2003 644 930 400 270 830
ACS800-07LC-1070-7 1×D3+2×R8i 2003 644 930 400 270 830
ACS800-07LC-1370-7 1×D4+2×R8i 2003 644 930 400 270 870
ACS800-07LC-1590-7 1×D4+3×R8i 2003 644 1130 400 270 1040
ACS800-07LC-2030-7 1×D4+3×R8i 2003 644 1130 400 270 1040
ACS800-07LC-2680-7 2×D4+4×R8i 2003 644 1830 400 270 1660
ACS800-07LC-3330-7 2×D4+5×R8i 2003 644 2030 400 270 1910
ACS800-07LC-3970-7 2×D4+6×R8i 2003 644 2230 400 270 2080
ACS800-07LC-4630-7 3×D4+7×R8i 2003 644 2930 400 270 2780
ACS800-07LC-5300-7 3×D4+8×R8i 2003 644 3130 400 270 2950
ACS800-07LC-5960-7 3×D4+9×R8i 2003 644 3330 400 270 3120
ACS800-07LC-6620-7 3×D4+10×R8i 2003 644 3630 400 270 3400
PDM-00430970-A.6
1) Free space above to allow opening of pressure relief vents (that open automatically upon arc fault)
2) Free space on the hinge side of the cabinet. Extra space is needed to make the door open fully when the
converter module is being pulled out of the cubicle.
Depth Depth excluding the door equipment (switches, handles, etc.).
Width 1 Basic unit with no options (6- or 12-pulse supply, no main breaker, no RFI filter +E202, no common
output terminals). For more information, see Cubicle widths and positions in cabinet line-ups on page
162.
Weight Weight of basic unit (no options) with an empty cooling circuit
Index – Each cubicle has a predesigned position in the supply unit line-up which is indicated by an index. The lower
the index, the further left the cubicle is positioned in the unit.
Abbreviations and option codes – The table below describes the abbreviations of the cubicle and module names.
The table also shows the option codes which indicate the use of certain optional cubicle.
Index – Each cubicle has a predesigned position in the inverter unit line-up which is indicated by an index. The lower
the index, the further left the cubicle is positioned in the unit.
Abbreviations – The table below describes the abbreviations of the cubicle and module names.
Abbr. Description
NBRW Brake chopper module / cubicle
SAFUR Brake resistor module / cubicle
Option codes – The table below shows which chopper and resistor cubicles are in use depending on the option
codes selected.
Index – Each cubicle has a predesigned position in the brake unit line-up which is indicated by an index (shown in
data tables later in this chapter). The lower the index, the further left the cubicle is positioned in the unit.
Abbreviations – The table below describes the abbreviations of the cubicle names.
Abbr. Description
LCU Cooling unit cubicle
Option codes – The table below shows the cooling unit position (either at the end of the drive cabinet line-up, or
stand-alone) and size depending on the option codes selected.
Option code Description
+C138 Line-up connected cooling unit
+C139 Stand-alone cooling unit
+C140 Single-pump cooling unit (ACS800-1007LC-0070)
+C141 Two-pump cooling unit (ACS800-1007LC-0195)