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ACS800-01
ABB ACS800-01 User Manual
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Maintenance 101
Fan replac
ement (R6)
Note:
In -0205-3 and 0255-5 units, acces
s the f
an through the opening in the support
frame of
the cable con
nection box.
1.
Remo
ve the scr
ew tha
t attaches the fan cas
ing and let the
casing lean down
against the limiters.
2.
Slide the cable connector out and disconnect it.
3.
T
ak
e off the
casing and r
eplace the f
an onto the casing pins.
4.
Reinst
all
the ca
sing
in reverse
order
.
1
2
3
102
104
Table of Contents
Default Chapter
5
Table of Contents
5
1 Safety Instructions
11
What this Chapter Contains
11
Use of Warnings and Notes
11
Installation and Maintenance Work
12
Grounding
13
Mechanical Installation and Maintenance
14
Printed Circuit Boards
14
Fiber-Optic Cables
14
Operation
15
Permanent Magnet Motor
16
Installation and Maintenance Work
16
Start-Up and Operation
16
2 Introduction to this Manual
17
What this Chapter Contains
17
Intended Audience
17
Categorization by Frame Size
17
Categorization According to the + Code
18
Contents
18
Installation and Commissioning Flowchart
19
Terms and Abbreviations
21
3 Operation Principle and Hardware Description
23
What this Chapter Contains
23
Product Overview
24
Type Code
25
Main Circuit and Control
26
Diagram
26
Operation
26
Printed Circuit Boards
27
Motor Control
27
4 Mechanical Installation
29
What this Chapter Contains
29
Unpacking the Unit
29
Example 1
30
Example 2
31
Checking the Delivery
32
Before Installation
32
Requirements for the Installation Site
32
Wall
32
Floor
32
Free Space Around the Unit
33
Mounting the Drive on the Wall
34
Units Without Vibration Dampers
34
IP55 (UL Type 12) Marine Applications (+C132) of Frame Sizes R4 to R6
34
Units with Vibration Dampers (+C131)
34
UL 12 Units
34
Cabinet Installation
35
Preventing Cooling Air Recirculation
35
Unit above Another
35
5 Planning the Electrical Installation
37
What this Chapter Contains
37
Motor Selection and Compatibility
38
Protecting the Motor Insulation and Bearings
39
Requirements Table
40
Permanent Magnet Motor
44
Supply Connection
45
Disconnecting Device
45
Fuses
45
Main Contactor
45
Thermal Overload and Short-Circuit Protection
46
Thermal Overload Protection of the Drive and the Input and Motor Cables
46
Thermal Overload Protection of the Motor
46
Sensors
46
Protecting the Motor and Motor Cable in Short Circuits
47
Protection against Short Circuits in the Drive or Supply Cable
48
Fuses
48
Circuit Breaker
48
Ground Fault Protection
49
Prevention of Unexpected Start-Up (Option +Q950)
49
Safe Torque off (Option +Q967)
50
Safe Torque off Circuit Diagram
51
Selecting the Power Cables
52
Alternative Power Cable Types
53
Motor Cable Shield
54
Additional US Requirements
54
Conduit
54
Armored Cable / Shielded Power Cable
54
Power Factor Compensation Capacitors
55
Equipment Connected to the Motor Cable
55
Installation of Safety Switches, Contactors, Connection Boxes, Etc
55
Bypass Connection
55
Using a Contactor between the Drive and the Motor
56
Tive Loads
57
Selecting the Control Cables
58
Relay Cable
58
Control Panel Cable
58
Connection of a Motor Temperature Sensor to the Drive I/O
59
Installation Sites above 2000 Metres (6562 Feet)
59
Routing the Cables
60
Control Cable Ducts
60
6 Electrical Installation
61
What this Chapter Contains
61
Checking the Insulation of the Installation
61
Drive
61
Supply Cable
61
Motor and Motor Cable
62
IT (Ungrounded) Systems
62
Connecting the Power Cables
63
Diagram
63
Conductor Stripping Lengths
64
Allowed Wire Sizes, Tightening Torques
64
Wall-Mounted Units (European Version)
64
Power Cable Installation Procedure
64
Wall-Mounted Units (US Version)
68
Warning Sticker
69
Cabinet Installation (IP21, UL Type 1)
70
Frame Size R5
70
Frame Size R6
71
Connecting the Control Cables
72
Terminals
72
360-Degree Grounding
74
Connecting the Shield Wires
74
Cabling of I/O and Fieldbus Modules
75
Pulse Encoder Module Cabling
75
Attaching the Control Cables and Covers
76
Installation of Option Modules and PC
76
Fiber-Optic Link
76
7 Installation of the AGPS Board (Prevention of Unexpected Start-Up, +Q950)
77
What this Chapter Contains
77
Prevention of Unexpected Start-Up (+Q950)
77
Installation of the AGPS Board
77
Circuit Diagram
80
Start-Up and Validation
81
Use
81
Maintenance
81
Dimensional Drawing
81
8 Installation of the ASTO Board (Safe Torque Off, +Q967)
83
What this Chapter Contains
83
Safe Torque off (+Q967)
83
Installation of the ASTO Board
83
Circuit Diagram
86
Start-Up and Validation
86
Dimensional Drawing
86
9 Motor Control and I/O Board (RMIO)
87
What this Chapter Contains
87
Note on Terminal Labelling
87
Note on External Power Supply
87
Parameter Settings
88
External Control Connections (Non-US)
89
External Control Connections (US)
90
RMIO Board Specifications
91
Analogue Inputs
91
Constant Voltage Output
91
Auxiliary Power Output
91
Analogue Outputs
91
Digital Inputs
91
Relay Outputs
92
DDCS Fibre Optic Link
92
DC Power Input
92
10 Installation Checklist
95
What this Chapter Contains
95
Checklist
95
11 Start-Up and Use
97
What this Chapter Contains
97
Start-Up Procedure
97
Control Panel
98
Removing the Control Panel
98
12 Maintenance
99
What this Chapter Contains
99
Safety
99
Maintenance Intervals
99
Heatsink
100
Fan
100
Fan Replacement (R2, R3)
100
Fan Replacement (R4)
101
Fan Replacement (R5)
102
Fan Replacement (R6)
103
Additional Fan
104
Replacement (R2, R3)
104
Replacement (R4, R5)
104
Replacement (R6)
104
Capacitors
105
Reforming
105
Leds
105
13 Technical Data
107
What this Chapter Contains
107
IEC Data
108
Ratings
108
Symbols
110
Sizing
110
Derating
111
Temperature Derating
111
Altitude Derating
111
Fuses
111
Frame Sizes R2 to R4
111
Frame Sizes R5 and R6
113
Calculation Example
113
Fuse Tables for Frame Sizes R5 and R6
114
Standard Gg Fuses
114
Ultrarapid (Ar) Fuses
116
Quick Guide for Selecting between Gg and Ar Fuses
117
Cable Types
119
Cable Entries
120
Dimensions, Weights and Noise
120
Package Dimensions and Weights
120
NEMA Data
121
Ratings
121
Symbols
122
Sizing
122
Derating
122
Fuses
123
Cable Types
124
Cable Entries
125
Dimensions, Weights and Noise
125
Package Dimensions and Weights
125
Input Power Connection
126
Motor Connection
126
Efficiency
126
Energy Efficiency Data (Ecodesign)
127
Cooling
127
Degree of Protection
127
AGPS-11C (Option +Q950)
127
ASTO-11C (Option +Q967)
127
Ambient Conditions
128
Materials
129
Applicable Standards
129
CE Marking
130
Compliance with the European Low Voltage Directive
130
Compliance with the European EMC Directive
130
Compliance with the European Machinery Directive
130
Compliance with en 61800-3:2004
130
Definitions
130
First Environment (Drive of Category C2)
131
Second Environment (Drive of Category C3)
131
Second Environment (Drive of Category C4)
132
C-Tick" Marking
132
Marine Type Approvals
132
UL/CSA Markings
133
UL Checklist
133
Disclaimer
133
Cybersecurity Disclaimer
133
14 Dimensional Drawings
135
Frame Size R2 (IP21, UL Type 1)
136
Frame Size R2 (IP55, UL Type 12)
137
Frame Size R3 (IP21, UL Type 1)
138
Frame Size R3 (IP55, UL Type 12)
139
Frame Size R4 (IP21, UL Type 1)
140
Frame Size R4 (IP55, UL Type 12)
141
Frame Size R5 (IP21, UL Type 1)
142
Frame Size R5 (IP55, UL Type 12)
143
Frame Size R6 (IP21, UL Type 1)
144
Frame Size R6 (IP21, UL Type 1), -205-3 and -255-5 Units
145
Frame Size R6 (IP55, UL Type 12)
146
Frame Size R6 (IP55, UL Type 12) -0205-3 and -0255-5 Units
147
Dimensional Drawings (USA)
148
Frame Size R2 (UL Type 1, IP21)
149
Frame Size R2 (UL Type 12, IP55)
150
Frame Size R3 (UL Type 1, IP21)
151
Frame Size R3 (UL Type 12, IP55)
152
Frame Size R4 (UL Type 1, IP21)
153
Frame Size R4 (UL Type 12, IP55)
154
Frame Size R5 (UL Type 1, IP21)
155
Frame Size R5 (UL Type 12, IP55)
156
Frame Size R6 (UL Type 1, IP21)
157
Frame Size R6 (UL Type 1, IP21) -0205-3 and -0255-5 Units
158
Frame Size R6 (UL Type 12, IP55)
159
Frame Size R6 (UL Type 12, IP55) -0205-3 and -0255-5 Units
160
AGPS Board (Option +Q950)
161
ASTO Board with Enclosure (Option +Q967)
162
15 Resistor Braking
163
What this Chapter Contains
163
Availability of Brake Choppers and Resistors for the ACS800
163
Selecting the Correct Drive/Chopper/Resistor Combination
163
Optional Brake Chopper and Resistor(S) for the ACS800-01/U1
165
Resistor Installation and Wiring
167
Protection of Frame Sizes R2 to R5 (ACS800-01/U1)
168
Protection of Frame Size R6
168
Brake Circuit Commissioning
169
16 External +24 V DC Power Supply for the RMIO Board Via Terminal X34
171
What this Chapter Contains
171
Parameter Settings
171
Connecting +24 V DC External Power Supply
172
17 RDCO-01/02/03/04 DDCS Communication Option Modules
175
What this Chapter Contains
175
Overview
175
Delivery Check
176
Module Layout
176
Installation
177
Installation Procedure
177
Technical Data
178
Further Information
179
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ABB ACS800-01 Specifications
General
Brand
ABB
Model
ACS800-01
Category
Controller
Language
English
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