ABB ACS800-37LC-0350-3, ACS800-37LC, ACS800-37LC-0430-3, ACS800-37LC-0580-3, ACS800-37LC-0870-3 Hardware Manual

...

ABB industrial drives

Hardware manual

ACS800-17LC Drives (55 to 5200 kW)

List of related manuals

Drive hardware manuals Code (English)

ACS800-17LC Hardware Manual 3AUA0000065339 ACS800 IGBT Supply Control Program Firmware Manual 3AFE68315735 ACS800 Standard Control Program Firmware Manual 3AFE64527592

Option manuals and guides

ACS800-1007LC Liquid Cooling Unit User’s Manual 3AFE68621101 ACS800-607LC 3-phase Brake Units Hardware Manual 3AFE68835861 ACS800 Brake Control Program Firmware Manual 3AFE68835631 ACW 621 Braking Chopper Sections User’s Manual 3BFE64314874 ACS800 Sine Filters User’s Manual 3AFE68389178

Fieldbus Adapters, I/O Extension Modules etc.

You can find manuals and other product documents in PDF format on the Internet. See section Document

library on the Internet on the inside of the back cover. For manuals not available in the Document library,

contact your local ABB representative.

ACS800-17LC Drives

55 to 5200 kW

Hardware Manual

3AUA0000065339 REV B EN

EFFECTIVE: 2016-06-07

Update notice

Code Revision Language

3AFE68715474 C English EN

3AFE68843723 B

German DE

3AFE68843731 B

Finnish FI

3AFE68843740 B

Italian IT

3AFE68843758 B

Swedish SV

3AFE68822092 B

English EN

3AFE68912148 B

German DE

3AFE68912156 B

Finnish FI

3AFE68912164 B

Italian IT

3AFE68912172 B

Swedish SV

3AFE68715491

C English EN

3AFE68987784

C German DE

3AFE68987792

C Finnish FI

3AFE68987806

C Italian IT

3AFE68987814

C Swedish SV

3AFE68835861 D English EN

3AUA0000040346 D

German DE

3AUA0000040370 D

Finnish FI

3AUA0000040368 D

Italian IT

3AFE68621101 E

English EN

3AFE68829887 E

German DE

3AFE68829909 E

Finnish FI

3AFE68829917 E

Italian IT

3AFE68829925 E

Swedish SV

3AFE68620902 E

English EN

3AFE68820821 E

German DE

3AFE68820847 E

Finnish FI

3AFE68820855 E

Italian IT

3AFE68820863 E

Swedish SV

3AUA0000065339 B

English EN

3AUA0000065342 B

English EN

ACS800LC liquid-cooled industrial units and drives coolant change to Antifrogen® L.

Code: 3AXD50000371952 Rev A

Val id : 2019-05-01

Contents:

This notice concerns industrial ACS800 Liquid-cooled multidrive Units Hardware manuals, ACS800 Liquid-cooled Single Drive cabinet manuals, ACS800 Liquid Cooling Unit User's Manual and their respective translations.

Update notice

Scope

This change concerns ACS800 Liquid-cooled multidrive Units (ACS800-107LC, 207LC, -307LC, -507LC, -607LC, -1107LC, -1207LC), ACS800-1007LC Liquid Cooling Unit, ACS800-07LC Drives, ACS800-17LC Drives and ACS800-37LC Drives manufactured in Finland or Estonia.

New units and drives are tested with Antifrogen® L. Antifrogen® L is a ready-made propylene glycol based coolant mixture with corrosion inhibitors included. Proper selection of Antifrogen® L and Adjustment of the Main Choke Valve is described in the document Usage of Antifrogen® L in ACS800LC Drives (3AXD10000511935).

New units and drives which are tested with Antifrogen® L must be operated with Antifrogen® L to prevent corrosion in the system. If usage of the old propylene glycol and corrosion inhibitor Cortec VpCl-649 in new Antifrogen® L tested units and drives is wanted system must be flushed before as Antifrogen® L remains in the system after testing. Flushing procedure described in the document Usage of Antifrogen® L in ACS800LC Drives (3AXD10000511935) must be followed. If new units or drives tested with Antifrogen® L are connected to old ACS800 industrial liquid-cooled units or drives, both systems needs to use same the coolant. Mixing propylene glycol and corrosion inhibitor Cortec VpCl-649 coolant with Antifrogen® L is not allowed.

New units and drives are tested with Antifrogen® L are labelled with information label (3AXD50000431427) below. The label is installed to LCU-cabinet or incoming main pipe of the unit if delivered without LCU-cabinet.

This update notice and Usage of Antifrogen® L in ACS800LC Drives (3AXD10000511935) document are delivered with drive in documentation pocket inside the cabinet door.

Update notice

Changes to documentation

Replaced Technical data, internal cooling circuit data, Water, Inhibitor, Glycol, Liquid mixture quality, Temperature limits, Pressure limits and Freeze protection and corrosion inhibition chapters to following:

Technical data

Coolant specification

Coolant type

Antifrogen®L (by Clariant International Ltd., www.clariant.com) 25% or 50% water mixture, available from Clariant distributors and ABB Service representatives.

Antifrogen®L 25% mixture is usable in storage temperatures down to -16 °C (3.2 °F). Antifrogen®L 50% mixture is usable in storage temperatures down to -40 °C (40 °F).

Note that operation below 0 °C (32 °F) is not allowed regardless of the freezing point of the coolant.

WARNING!

Temperature limits

Ambient temperature: See the technical data of the drive/unit.

Freeze protection: The freezing point of the coolant is determined by the

concentration of heat transfer fluid in the mixture.

The higher the concentration of heat transfer fluid, the higher the viscosity of the coolant. This results in a higher pressure loss in the system.

The nominal current ratings of drive system modules apply to Antifrogen®L / water solution of 25/75 (volume). For derating with other ratios, contact your local ABB representative.

The warranty does not cover damage occurring from use of improper coolant.

Update notice

The temperature of the coolant must be controlled according to the tables below.

Minimum coolant inlet temperature: Condensation is not allowed. The minimum coolant temperature to avoid concentration (at an atmospheric pressure of 100 kPa) is shown below as a function of the relative humidity ( (T

air

(°C) Min. T

air

ϕ = 95% ϕ = 80%

coolant

ϕ = 65% ϕ = 50% ϕ = 40%

ϕ) and the ambient temperature

(°C)

10 9.2 6.7

15 14.2 11.5 8.4

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

4.3 1.9 -0.9 -4.5 -7.4

3.7 -0.1 -3.0

4.6 1.5

= Not allowed as standard but the coolant temperature must be 5 °C or above. Consult an ABB representative if operation below coolant temperature 5 °C is required.

Example: At an air temperature of 45 °C and relative humidity of 65% the coolant temperature may not be below +36.8 °C.

Maximum coolant inlet temperature for ACS800 liquid cooled drive

Update notice

Drive with the optional cooling unit (ACS800-1007LC):

• 38 °C when the drive output capacity is not derated

• 38 °C...45 °C when the drive output capacity is derated by 1% per 1 °C temperature increase.

Drive without the optional liquid cooling unit (ACS800-1007LC):

• 42 °C when the drive output capacity is not derated

• 42 °C...48 °C when the drive output capacity is not derated by 1% per 1 °C temperature increase.

Maximum temperature rise: 13 °C, depends on the mass flow.

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

Design pressure (Ps): 600 kPa

Nominal pressure difference (between main in/out lines): 120 kPa with 25(75%

(volume) coolant solution, 150 kPa with 50/50% coolant solution.

Maximum pressure difference (between main in/out lines): 200 kPa

Update notice

Table of contents

Safety instructions

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Use of warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Safety in installation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Electrical safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Fiber optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Use of the hand-operated winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Work on the liquid cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Safe start-up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Introduction to the manual

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Categorization by frame size and option code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Quick installation and start-up flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Hardware description

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Single-line circuit diagram of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Example circuit diagram (frames R7i+R7i and R8i+R8i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Example circuit diagram (frame 2×R8i+2×R8i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Block diagram of the main circuit with options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

General information on drive cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Cabinet layout (frames R7i+R7i and R8i+R8i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Swing-out frame layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Auxiliary control cubicle layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Main switch disconnecter cubicle layout (frames 2×R8i+2×R8i and up) . . . . . . . . . . . . . . . . . . . . . 35

600 mm wide cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

1000 mm wide cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Table of contents

Layout of LCL filter and supply module cubicles (frame 2×R8i and up) . . . . . . . . . . . . . . . . . . . . . .36

Swing-out frame layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Layout of inverter module cubicle (frame 2×R8i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Layout of inverter module cubicle (frame 3×R8i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Layout of inverter module cubicles (frames 4×R8i to 9×R8i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Swing-out frame layout of the inverter module cubicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Overview of supply and inverter modules (R7i and R8i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Overview of power and control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

Control of the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Main switch-disconnector Q1 (frames R7i+R7i and R8i+R8i) . . . . . . . . . . . . . . . . . . . . . . . . .43

Supply transformer disconnecting push button (+Q959) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Operating switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Auxiliary power switch Q100 (frame sizes 2×R8i and up) . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Grounding switch Q9 (option +F259) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Emergency stop push button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Reset button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Connections and use of the I/O in the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Connections to standard I/O terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Control of the inverter unit and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Connections and use of the I/O in the inverter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Type designation labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Drive label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Supply, inverter and brake module label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Type code of the basic configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Option codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Mechanical installation

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Checking the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Checking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Moving the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Moving the unit by crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Moving the unit by fork-lift or pallet truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Moving the unit on rollers (not allowed with marine cabinets) . . . . . . . . . . . . . . . . . . . . . . . . .57

Laying the unit on its back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Placing the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Overview of the installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Fastening the cabinet to the floor and wall (non-marine units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Alternative 1 – Clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Alternative 2 – Using the holes inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Fastening the unit to the floor and wall (marine units, option +C121) . . . . . . . . . . . . . . . . . . . . . . .62

Joining the shipping splits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Preparing the liquid pipe connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Fastening the cabinets together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Connecting the liquid pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

Table of contents

Connecting the PE busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Connecting the DC busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Cable duct in the floor below the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Electric welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Planning the electrical installation

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Selecting the supply disconnecting device (disconnecting means) . . . . . . . . . . . . . . . . . . . . . . . . . 69

Checking the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Requirements for motor insulation and bearings and drive filters . . . . . . . . . . . . . . . . . . . . . 71

Explosion-safe (EX) motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

High-output motors and IP 23 motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

HXR and AMA motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

ABB motors of types other than M2_, M3_, HX_ and AM_ . . . . . . . . . . . . . . . . . . . . . 73

When DC link voltage is increased with parameter settings . . . . . . . . . . . . . . . . . . . . . 73

Calculating the rise time and the peak line-to-line voltage . . . . . . . . . . . . . . . . . . . . . . 73

Sine filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Coaxial cable (for use with Advant Controllers AC 80/AC 800) . . . . . . . . . . . . . . . . . . . . . . . 80

Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Protecting the drive, input power cable, motor and motor cable in short circuit situation and against

thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Protecting the drive and input power cable in short-circuit situations . . . . . . . . . . . . . . . . . . 81

Protecting the motor and motor cable in short-circuit situations . . . . . . . . . . . . . . . . . . . . . . 82

Protecting the drive, motor cable and input power cable against thermal overload . . . . . . . . 82

Protecting the motor against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Insulation requirements for the motor temperature sensor circuit . . . . . . . . . . . . . . . . 83

Protecting the drive against ground faults in the drive, motor or motor cable . . . . . . . . . . . . . . . . . 83

Implementing the emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Implementing the Prevention of unexpected start function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Implementing the Safe torque off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Implementing the power-loss ride-through function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Supplying power for the auxiliary circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Terminals for connecting external control voltage (option +G307) . . . . . . . . . . . . . . . . . . . . 86

Units without optional auxiliary control transformer and without terminals for connecting external

Table of contents

control voltage (option +G307) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

Using power factor compensation capacitors with the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

Implementing a safety switch between the drive and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Using a contactor between the drive and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Implementing a bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Example bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Switching the motor power supply from drive to direct-on-line . . . . . . . . . . . . . . . . . . .88

Switching the motor power supply from direct-on-line to drive . . . . . . . . . . . . . . . . . . .89

Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Considering the PELV on installation sites above 2000 metres (6562 feet) . . . . . . . . . . . . . . . . . .90

Electrical installation

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Supply cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

Braking resistor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

Checking the compatibility with IT (ungrounded) and corner grounded TN systems . . . . . . . . . . . .92

Connecting the input power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Connecting the motor cable – units with no common motor terminals cubicle option +H359 . . . . .94

Connection diagram – single inverter module feeds one motor . . . . . . . . . . . . . . . . . . . . . . .94

Connection diagram – parallel inverter modules feed one motor . . . . . . . . . . . . . . . . . . . . . .95

Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

Connecting the motor cable (units with the common motor cable connection terminals cubicle option

+H359) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

Connecting external power supply for the auxiliary circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

Frames R7i×R7i and R8i×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

Frames 2×R8i and up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

Standard unit without optional auxiliary control voltage transformer or terminals for con-

necting external control voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

Units with optional auxiliary control voltage transformer and without terminals for connect-

ing external control voltage (+G307) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

Units with terminals for connecting external control voltage (option +G307) and without op-

tional auxiliary control voltage transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102

Connecting the control cables for the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102

Connecting the control cables for the inverter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

Default I/O connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105

Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

Installing optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

Cabling of I/O and fieldbus modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

Cabling of pulse encoder interface module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

Fiber optic links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

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Installation checklist

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Start-up

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Checks with no voltage connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Connecting voltage to the input terminals and auxiliary circuit . . . . . . . . . . . . . . . . . . . . . . 112

Closing the main contactor/breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Checking the setting of the ground fault monitoring device . . . . . . . . . . . . . . . . . . . . . . . . . 112

Supply unit control program set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Inverter unit control program set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Liquid cooling unit control program set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

On-load checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Switching the control panel between the supply and inverter units . . . . . . . . . . . . . . . . . . . . . . . . 114

ACS800-17LC-specific parameters in the IGBT Supply Control Program . . . . . . . . . . . . . . . . . . 115

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Default values of parameters with the ACS800-17LC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

ACS800-17LC-specific parameters in the application program . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Actual signals and parameters of supply unit in inverter unit program . . . . . . . . . . . . . . . . 117

Fault tracing

LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Warning and fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Warning/Fault message from the unit not being monitored by the control panel . . . . . . . . . 119

Conflicting ID numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Maintenance

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Replacing the cooling fan of converter module (frames R7i and R8i) . . . . . . . . . . . . . . . . . 121

Replacing the additional fan in the incoming cubicle (frames R7i+R7i and R8i+R8i) . . . . . 122

Replacing the auxiliary control cubicle fan (frames 2×R8i+2×R8i and up) . . . . . . . . . . . . . 123

Replacing the fan in the incoming cubicle (frames 2×R8i+2×R8i and up) . . . . . . . . . . . . . . 124

Replacing the cooling fans in supply module cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Replacing the inverter module fans (2×R8i and up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Replacing the additional fan in the common motor terminals cubicle . . . . . . . . . . . . . . . . . 126

Reduced run capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Replacing supply and inverter modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Installing the winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Installing the installation stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

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Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134

Replacing the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134

Cleaning the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134

Replacing the PPCS branching unit (APBU-xx) memory backup battery . . . . . . . . . . . . . . . . . . .135

Internal cooling circuit

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137

Internal cooling system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137

Connection to a cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

Connection to an ACS800-1007LC cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

Connection to a custom cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

General requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

Coolant temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

Filling up and bleeding the internal cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139

Drive line-ups with an ACS800-1007LC cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139

Drive line-ups with a custom cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139

Draining the internal cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140

Adding inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141

Temperature limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141

Pressure limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141

Water quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142

Freeze protection and corrosion inhibition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142

Glycol concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

Technical data

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146

Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146

Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146

Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147

Type equivalence table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147

1-phase brake choppers (option +D150) and resistors (option +D151) . . . . . . . . . . . . . . . . . . . . .148

3-phase brake units (option +D152) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150

Main circuit AC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150

Main circuit DC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151

Dimensions, weights and free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152

Losses, cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153

Internal cooling circuit data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154

Terminal and lead-through data for the input power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155

Terminal and lead-through data for the motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156

Units without common motor terminal cubicle (no option +H359) . . . . . . . . . . . . . . . . . . . . .156

Units with the Common Motor Terminal (CMT) cubicle (option +H359) . . . . . . . . . . . . . . .157

Table of contents

Terminal and lead-through data for the resistor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Terminal and lead-through data for the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Electrical power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Motor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Brake resistor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Control unit (RDCU/RMIO) connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Analog inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Constant voltage output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Auxiliary power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Analog outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

DDCS fibre optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

24 V DC power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Isolation and grounding diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Auxiliary circuit current consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Compliance with EN 61800-3:2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Category C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Category C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

CSA marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Cyber security disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Dimensions

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Table of dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Frame sizes R7i+R7i and R8i+R8i (bottom entry/exit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Frame sizes R7i+R7i and R8i+R8i (marine units, +C121) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Providing feedback on ABB manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Table of contents

Safety instructions

What this chapter contains

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

Use of warnings

Warnings caution you about conditions which can result in serious injury or death and/or damage to the equipment, and advise on how to avoid the danger. The following warning symbols are used in this manual:

Electricity warning warns of hazards from electricity which can cause physical injury and/or damage to the equipment.

General warning warns about conditions, other than those caused by electricity which can result in physical injury and/or damage to the equipment.

Electrostatic sensitive devices warning warns of electrostatic discharge which can damage the equipment.

Safety instructions

Safety in installation and maintenance

Electrical safety

These warnings are intended for all who work on the drive, motor cable or motor.

WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment:

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

• Before working on the drive, isolate the whole drive from the supply. The main switch on the cabinet door 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 switching off the input power, always wait for 5 min to let the intermediate circuit capacitors discharge before you start working on the drive, motor or motor cable. Measure the voltage between + and - DC busbars 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 cause dangerous voltages inside the drive even when the main power on the drive is switched off.

• Do not make any insulation or voltage withstand tests on the drive or drive modules.

• When reconnecting the motor cable, always check that the phase order is correct.

• When joining shipping splits (if any), check the cable connections at the joints before switching on the supply voltage.

• Live parts on the inside of the doors are protected against direct contact. Pay special attention when handling metallic shrouds.

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 and brake resistor terminals (R+, R-, R1.1, R1.2, R1.3, R2.1, R2.2. and R2.3) carry dangerous voltage (over 500 V).

• Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V) may be present on the relay outputs of the drive system.

• The Prevention of unexpected start function (option +Q950) and the Safe torque off function (option +Q968) do not remove the voltage from the main and auxiliary circuits.

Safety instructions

• At installation sites above 2000 m (6562 ft), the terminals of the RMIO board and optional modules attached to the board do not fulfil the Protective Extra Low Voltage (PELV) requirements stated in EN 61800-5-1.

Grounding

These instructions are intended for all who are responsible for the grounding of the drive.

WARNING! Ignoring the following instructions can cause physical injury, death, increased electromagnetic interference and equipment malfunction:

• Ground the drive, motor and adjoining equipment to ensure personnel safety in all circumstances, and to reduce electromagnetic emission and interference.

• 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 optional EMC filter +E202 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.

• As the normal leakage current of the drive is higher than 3.5 mA AC or 10 mA DC, a fixed protective earth connection is required by EN 61800-5-1, 4.3.5.5.2. See also Selecting the power cables, page 74.

Safety instructions

Permanent magnet motor drives

These are additional warnings concerning permanent magnet motor drives.

WARNING! Ignoring the following instructions can cause physical injury, death, increased electromagnetic interference and equipment malfunction:

• 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 there is no voltage on the drive power terminals according to step 1 or 2, or if possible, according to the both steps.

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 (L1, L2, L3, U1, V1, W1, U2, V2, W2, R+, R-).

2. Ensure that the motor cannot rotate during work. Make sure that no other system, like hydraulic crawling drives, is able to rotate the motor directly or through any mechanical connection like felt, nip, rope, etc. Measure that there is no voltage present on the drive input or output terminals (L1, L2, L3, U1, V1, W1, U2, V2, W2, R+, R-, R1.1, R1.2, R1.3, R2.1, R2.2. and R2.3). Ground the drive output terminals temporarily by connecting them together as well as to the PE.

Safety instructions

General safety

These instructions are intended for all who install and service the drive.

WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment:

• Cover the drive when installing to ensure that dust from borings and grindings or foreign objects do not enter the drive. Electrically conductive dust inside the unit may cause damage or lead to malfunction.

• Ensure sufficient cooling of the unit.

• Use extreme caution when manoeuvring heavy inverter, supply and 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.

• Pay attention to rotating cooling fans. The cooling fans may continue to rotate for a while after the disconnection of the electrical supply.

• Recommendation: Do not fasten the cabinet by riveting or welding. However, if electric welding is the only way to mount the cabinet, follow the instructions given in chapter Mechanical installation. Ensure that welding fumes are not inhaled. If the welding return wire is connected improperly, the welding circuit may damage electronic circuits in the cabinet.

Printed circuit boards

WARNING! Ignoring the following instructions can cause damage to the printed circuit boards:

The printed circuit boards contain components sensitive to electrostatic

•

discharge. Wear a grounding wrist band when handling the boards. Do not touch the boards unnecessarily.

Fiber optic cables

WARNING! Ignoring the following instructions can cause equipment malfunction and damage to the fiber optic cables:

Handle the fiber optic cables with care. When unplugging optic cables, always

•

grab the connector, not the cable itself. Do not touch the ends of the fibers with bare hands as the fiber is extremely sensitive to dirt. The minimum allowed bend radius is 35 mm (1.4 in.).

Safety instructions

2 mm

Use of the hand-operated winch

These instructions are intended for all who use the hand-operated winch delivered with the drive when replacing the supply or inverter modules.

WARNING! Ignoring these instructions can cause physical injury or death, or damage the to equipment.

• Before using the winch for the first time, spool out 2 meters (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.

Work on the liquid cooling system

These instructions are intended for all who are responsible for installation and maintenance work of the liquid cooling system of the drive.

WARNING! Ignoring the following instructions can cause physical injury or damage to the equipment:

• 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 (6 bar, max. 50°C) 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 (+C199, +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.

• Drain the unit before storing in temperatures below 0°C. Freezing of the liquid cooling system is not allowed. If the ambient temperature is below +5°C, add antifreeze and corrosion inhibitors to the cooling liquid. Operation at temperatures below zero is not permitted, not even with antifreeze.

Safety instructions

Safe start-up and operation

General safety

These warnings are intended for all who plan the operation of the drive or operate the drive.

WARNING! Ignoring the following instructions can cause physical injury or death or damage the equipment:

• 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.

• Do not activate automatic fault reset functions of the drive control program if dangerous situations can occur. When activated, these functions will reset the drive and resume operation after a fault.

• 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 ie, power-ups by applying power, is five in ten minutes.

• Do not use the Prevention of unexpected start function or Safe torque off function for stopping the drive when the inverter unit(s) is running. Give a Stop command instead.

Note:

• If an external source for start command is selected and it is ON, the drive (with Standard Control Program) will start immediately after fault reset unless the drive is configured for 3-wire (a pulse) start/stop.

• 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 .

Permanent magnet motor drives

These are additional warnings concerning permanent magnet motor drives.

WARNING! Do not run the motor above the rated speed. Motor overspeed leads to overvoltage which may result in explosion of the capacitors in the intermediate circuit of the drive.

Safety instructions

Introduction to the manual

What this chapter contains

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

Applicability

This manual applies to the hardware of the ACS800-17LC drives. For the firmwares and optional devices, see the appropriate manuals.

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. You are expected to know the fundamentals of electricity, wiring, electrical components and electrical schematic symbols.

Contents

The manual is written for readers worldwide. Both SI and imperial units are shown.

The chapters of this manual are briefly described below.

Safety instructions gives safety instructions for the installation, commissioning,

operation and maintenance of the drive.

Introduction to the manual introduces the manual. Hardware description describes the operation principle and construction 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 sizes and routing.

Electrical installation instructs the electrical of the drive. Installation checklist helps in checking the mechanical and electrical installation of

the drive.

Maintenance contains preventive maintenance instructions. Fault tracing contains troubleshooting instructions.

Introduction to the manual

Technical data contains the technical specifications of the drive eg, ratings, frame

sizes and technical requirements and provisions for fulfilling the requirements for CE and other markings.

Dimensions contains information on the dimensions of the drive.

ABB ACS800-37LC-0350-3, ACS800-37LC, ACS800-37LC-0430-3, ACS800-37LC-0580-3, ACS800-37LC-0870-3 Hardware Manual

Specifications and Main Features

Frequently Asked Questions

User Manual