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ACS850-04
Hardware Manual
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Table of contents
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ABB ACS850-04 Hardware Manual

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

List of related manuals

ACS850-04 manuals
Drive hardware manuals and guides Code (English)
guide
Drive firmware manuals and guides
Option manuals and guides
ACS-CP-U Control Panel IP54 Mounting Platform Kit (+J410) Installation Guide
application guide Application programming for ACS850 and ACQ810 drives application guide 3AUA0000078664 Manuals and quick guides for I/O extension modules, fieldbus adapters, 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.
3AFE68929814
3AUA0000049072
3AUA0000074343
ACS850-04 drive modules
160 to 560 kW (200 to 700 hp)
Hardware manual
2013 ABB Oy. All Rights Reserved.
3AUA0000081249 Rev C
EN
EFFECTIVE: 2013-04-11

Table of contents

List of related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
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
Fiber optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Safe start-up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
General safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5
Introduction to the manual
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Categorization by frame size and option code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Quick installation, commissioning and operating flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Operation principle and hardware description
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Power connections and control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
External control unit connection cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Planning the cabinet installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Limitation of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Basic requirements for the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Planning the layout of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Table of contents
6
Layout examples, door closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Layout example, door open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Arranging the grounding inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Selecting the busbar material and preparation of the joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Planning the fastening of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Planning the cabinet placement on a cable channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Planning the electromagnetic compatibility (EMC) of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . .41
Planning the grounding of the cable shields at the cabinet lead-through . . . . . . . . . . . . . . . . . . . . .43
Planning the cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Preventing the recirculation of hot air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Required free space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Free space at the top of the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Free space around the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Other installation positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Planning the placement of the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Planning the use of the cubicle heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Planning the electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Selecting the supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
European Union . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Other regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Selecting and dimensioning the main contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Checking the compatibility of the motor and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Additional requirements for explosion-safe (EX) motors . . . . . . . . . . . . . . . . . . . . . . . .53
Additional requirements for HXR and AMA motors . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_
and AM_ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Additional requirements for the braking applications . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Additional requirements for ABB high-output motors and IP23 motors . . . . . . . . . . . . .53
Additional requirements for non-ABB high-output and IP23 motors . . . . . . . . . . . . . . .54
Additional data for calculating the rise time and the peak line-to-line voltage . . . . . . . .55
Additional note for sine filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Additional note common mode filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Signals in separate cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Signals allowed to be run in the same cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Table of contents
Relay cable type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Control panel cable length and type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Separate control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Continuous motor cable shield or enclosure for equipment in the motor cable . . . . . . . . . . . 62
Implementing thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Protecting the drive and input power cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Protecting the motor and motor cable in short-circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Protecting the drive and the input power and motor cables against thermal overload . . . . . 63
Protecting the motor against thermal overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Protecting the drive against ground faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Residual current device compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Implementing the Emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Implementing the Safe torque off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Implementing the ATEX-certified Safe motor disconnection function (option +Q971) . . . . . . . . . . 64
Implementing the Power loss ride-through function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Using power factor compensation capacitors with the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Implementing a safety switch between the drive and motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Using a contactor between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Implementing a bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Example bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Switching the motor power supply from drive to direct-on-line . . . . . . . . . . . . . . . . . . . 67
Switching the motor power supply from direct-on-line to drive . . . . . . . . . . . . . . . . . . . 67
Protecting the contacts of relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Connecting a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Example circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7
Installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Checking the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Moving and unpacking the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Checking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Input cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Brake resistor and resistor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Overall flowchart of the installation process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Installing the mechanical accessories into the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Assembly drawing (frame G1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Assembly drawing (frame G2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Assembly drawing (air baffles) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Power cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Mounting the drive module into the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Table of contents
8
Mounting procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Assembly drawing of installing the drive module to the cabinet (frame G1) . . . . . . . . . . . . . .93
Assembly drawing of installing the drive module to the cabinet (frame G2) . . . . . . . . . . . . . .94
Removing the protective covering from the module air outlet . . . . . . . . . . . . . . . . . . . . . . . . .95
Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Flowchart of the control cable installation process (external control unit) . . . . . . . . . . . . . . . .95
Flowchart of the control cable installation process (internal control unit, option +P905) . . . . .95
Removing the cover assembly of the external control unit . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Fastening the control cable clamp plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Connecting the external control unit to the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Mounting the external control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Mounting the external control unit to wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Mounting the external control unit vertically on a DIN rail . . . . . . . . . . . . . . . . . . . . . .100
Mounting the control unit horizontally on a DIN rail . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Installing optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Wiring the modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Connecting the control cables to the terminals of the control unit . . . . . . . . . . . . . . . . . . . . .102
Default I/O connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
External power supply for the JCU control unit (XPOW) . . . . . . . . . . . . . . . . . . . . . . .106
DI6 (XDI:6) as a thermistor input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Drive-to-drive link (XD2D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Safe torque off (XSTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Control cable connection procedure of units with internal control unit (option +P905) . . . . . . . . . .108
Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Installation checklist
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Start-up
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Fault tracing
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Warning and fault messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Maintenance
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Table of contents
Cleaning the interior of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Cleaning the interior of the heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Replacing the circuit board compartment cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Replacing the main cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Replacing the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Memory unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Technical data
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Ambient temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Fuses (IEC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Ultrarapid (aR) fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
aR fuses with flush end contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Fuses (UL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
UL recognised Class T / Class L fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Dimensions, weights and free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Losses, cooling data and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Terminal and lead-through data for the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Units with optional common mode filter (+E208) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Units with optional cabling panels (+H381 or +H383) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Units without optional cabling panels (no +H381 or +H383) . . . . . . . . . . . . . . . . . . . . . . . . 130
Terminal data for the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Electrical power network specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Motor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Brake resistor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
DC connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Control unit (JCU-11) connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Compliance with EN 61800-3:2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Category C3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Category C4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
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10
CSA marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
“C-tick” marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
GOST R certificate of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Dimension drawings
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Frame G1 – Drive module dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Frame G1 – Drive module dimensions with optional cabling panels (+H381) . . . . . . . . . . . . . . . .143
Frame G1 – Cabling panels (+H383) installed into a Rittal TS 8 cabinet . . . . . . . . . . . . . . . . . . . .145
Frame G2 – Drive module dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
Frame G2 – Drive module dimensions with optional cabling panels (+H381) . . . . . . . . . . . . . . . .147
Frame G2 – Cabling panels (+H383) installed into a Rittal TS 8 cabinet . . . . . . . . . . . . . . . . . . . .149
Frames G1 and G2 – Bottom plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
Frames G1 and G2 – Air baffles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Example circuit diagram
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Example circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Resistor braking
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Availability of brake choppers and resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
When is resistor braking needed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Planning the braking system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Selecting the brake circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Placing the brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
Protecting the system in fault situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
Thermal overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
Short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
Selecting and routing the brake circuit cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
Minimizing electromagnetic interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
Maximum cable length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
EMC compliance of the complete installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Brake circuit commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
Brake resistor connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
SAFUR resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
Maximum resistor cable length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
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11
du/dt filters
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
du/dt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
When is du/dt filter needed? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Description, installation and technical data of the FOCH filters . . . . . . . . . . . . . . . . . . . . . . 161
Further information
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
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Table of contents

Safety instructions

What this chapter contains

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

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.
13
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.
Hot surface warning warns of component surfaces that may become hot enough to cause burns if touched.
Safety instructions
14

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.
•
Never work on the drive, motor cable or motor when main power is applied.
•
After disconnecting 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.
Always ensure by measuring with a multimeter (impedance at least 1 Mohm) that:
1. voltage between drive input phases U1, V1 and W1 and the frame is close to 0V.
2. voltage between terminals UDC+ and UDC- and the frame is close to 0 V.
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.
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 brake control terminals (UDC+, UDC-, R+ and R- terminals) carry a
•
dangerous DC voltage (over 500 V).
Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V)
•
may be present on the terminals of relay outputs (X2) or Safe torque off (X6).
The Safe torque off function does not remove the voltage from the main and
•
auxiliary circuits.
Safety instructions
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).
Where EMC emissions must be minimized, make a 360° high frequency
•
grounding of cable entries at the cabinet lead-through in order to suppress electromagnetic disturbances. In addition, connect the cable shields to protective earth (PE) in order to meet safety regulations.
15
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.
Safety instructions
16
Permanent magnet motor drives
These are additional warnings concerning permanent magnet motor drives.
WARNING! Ignoring the instructions can cause physical injury or death, or damage to the equipment.
• Do not work on the drive when the permanent magnet motor is rotating. Also, when the supply power is switched off and the drive is stopped, a rotating permanent magnet motor feeds power to the intermediate circuit of the drive and the supply connections become live.
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, output or DC terminals (U1, V1, W1, U2, V2, W2, UDC+, UDC-).
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, output or DC 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.
Safety instructions

General safety

1
2
3
3AUA0000086323
A
These instructions are intended for all who install and service the drive.
WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment:
- Lift the drive module using the lifting lugs attached to the top and base of the
•
unit.
- Handle the drive module carefully. Make sure that the module does not fall down when moving it on the floor and during installation and maintenance work: Open the support legs by pressing each leg a little down (1, 2) and turning it aside. When ever possible secure the module also with chains.
- Do not tilt the drive module (A). It is heavy (over 160 kg [350 lb]) and its center of gravity is high. The module will overturn from a sideways tilt of 5 degrees. Do not leave the module unattended on a sloping floor.
17
Safety instructions
18
3AUA0000086323
- Push the drive module into the cabinet and pull it from the cabinet carefully preferably with help from another person as shown below. Keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back. Use safety shoes with metal toe cap to avoid foot injury. Do not use the ramp with plinth heights which exceed the maximum height marked on the ramp next to the fastening screw. (The maximum plinth height is 50 mm when the telescopic ramp is shortest and 150 mm when the ramp is longest.) Tighten the two fastening bolts of the ramp carefully.
Beware of hot surfaces. Some parts, such as heatsinks of power
•
semiconductors, remain hot for a while after disconnection of the electrical supply.
Make sure that dust from borings and grindings does not enter the drive when
•
installing. Electrically conductive dust inside the unit may cause damage or malfunctioning.
Ensure sufficient cooling.
•
Do not fasten the drive by riveting or welding.
•
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
Printed circuit boards
WARNING! Ignoring the following instructions can cause damage to the printed circuit boards:
Wear a grounding wrist band when handling the boards. Do not touch the
•
boards unnecessarily. The printed circuit boards contain components sensitive to electrostatic discharge.

Safe start-up and operation

General safety

These warnings are intended for all who plan the operation of the drive or operate the drive.
WARNING! Ignoring the following instructions can cause physical injury or death, or damage to 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.
19
Do not activate any 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 an AC contactor or disconnecting device;
•
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.
Note:
If an external source for start command is selected and it is ON, the drive will
•
start immediately after an input voltage break or fault reset unless the drive is configured for 3-wire (a pulse) start/stop.
When the control location is not set to local, the stop key on the control panel
•
will not stop the drive.

Permanent magnet motor drives

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.
Safety instructions
20
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.

Target audience

This manual is intended for persons who
• plan the cabinet assembly of the drive module and install the module into a user­defined cabinet
• plan the electrical installation of the drive cabinet
• make instructions for the end user of the drive concerning the mechanical installation of the drive cabinet, connection of power and control cables to the cabinet-installed drive and maintenance of the drive.
21
Read the manual before working on the drive. You are 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.

Contents of the manual

This manual contains the instructions and information for the basic drive module configuration. The chapters of the manual are briefly described below.
Safety instructions give safety instructions for the installation, commissioning,
operation and maintenance of the drive module.
Introduction to the manual introduces the manual. Operation principle and hardware description describes the drive module. Planning the cabinet installation guides in planning drive cabinets and installing the
drive module into a user-defined cabinet. The chapter gives cabinet layout examples and free space requirements around the module for cooling.
Planning the electrical installation instructs in the motor and cable selection,
protections and cable routing.
Installation describes how to install the drive module into a cabinet and connect the
cables to the drive.
Installation checklist contains lists for checking the mechanical and electrical
installation of the drive.
Introduction to the manual
22
Start-up refers to the start-up instructions of the cabinet-installed drive. Fault tracing describes the LED indications and refers to the fault tracing instructions
of the drive.
Maintenance contains preventive maintenance instructions. Technical data contains the technical specifications of the drive module, eg, the
ratings, sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings.
Dimension drawings contains dimension drawings of the drive module installed into
a Rittal TS 8 cabinet.
Example circuit diagram shows an example circuit diagram for a cabinet-installed
drive module.
Resistor braking describes how to select, protect and wire brake resistors. du/dt filters describes how to select du/dt filters for the drive.

Categorization by frame size and option code

The instructions, technical data and dimension drawings which concern only certain drive frame sizes are marked with the symbol of the frame size (G1 or G2). The frame size is marked on the type designation label.
The instructions and technical data which concern only certain optional selections are marked with option codes, eg, +H381. The options included in the drive can be identified from the option codes visible on the type designation label. The option selections are listed in section Type designation key on page 35.

Quick installation, commissioning and operating flowchart

Task See
Plan the installation. Check the ambient conditions, ratings, required
cooling air flow, input power connection, compatibility of the motor, motor connection, and other technical data.
Select the cables.
Unpack and check the units. Check that all necessary optional modules and
equipment are present and correct. Only intact units may be started up.
Planning the cabinet installation (page 37) Planning the electrical installation (page 49) Technical data (page 125) Resistor braking (page 155)
Option manual (if optional equipment is included)
Moving and unpacking the unit (page 74) Checking the delivery (page 76)
If the drive module has been non-operational for more than one year, the converter DC link capacitors need to be reformed. (Reforming the
capacitors, page 124)
Introduction to the manual
Task See
23
Check the installation site. Fasten the base of the cabinet to floor.
Route the cables. Routing the cables (page 60)
Check the insulation of the supply cable, the motor and the motor cable and the resistor cable (if present).
Units with optional cabling panels (+H
• Install the cabling panels into the cabinet.
• Install the additional components into the cabinet (composition varies, for example: main disconnector, main contactor, main AC fuses, etc.).
• If the main disconnector is installed into the cabinet, connect the input power cabling to it.
• Connect the input power cables and motor cables to the cabling panel terminals.
• Connect the brake resistor and DC connection cables (if any) to the cabling panel terminals.
• Install the drive module into the cabinet.
• Fasten the cabling panel busbars to the drive module busbars.
• If external drive control unit, connect the power supply and fiber optic cables from the drive module to the control unit and install the control unit into the cabinet.
Units without optional cabling panels (no +H +H383)
• Install the additional components into the cabinet (composition varies, for example: main PE busbar, main disconnector, main contactor, main AC fuses, etc.).
• Install the drive module into the cabinet.
• Connect the power cabling between the drive module and the rest of the main circuit components in the cabinet (if any).
• Connect the input power cables and motor cables to the drive cabinet.
• Connect the brake resistor and DC connection cables to the drive cabinet.
• If external drive control unit, connect the power supply and fiber optic cables from the drive module to the control unit and install the control unit into the cabinet.
381 or +H383)
381 or
Checking the installation site (page 73) Ambient conditions (page 134) Planning the cabinet installation (page 37)
Checking the insulation of the assembly (page
76)
Installing the mechanical accessories into the cabinet (page 79)
Connecting the power cables (page 84) Mounting the drive module into the cabinet
(page 89)
Connecting the external control unit to the drive module (page 97)
Mounting the external control unit (page 99)
Manuals for any optional equipment
Introduction to the manual
24
Task See
Connect the external control cables to the drive control unit.
Check the installation. Installation checklist (page 109)
Commission the drive. Start-up (page 113)
Commission the brake chopper (if used). Resistor braking (page 155)
Operating of the drive: start, stop, speed control etc. Appropriate firmware manual

Terms and abbreviations

Term/Abbreviation Explanation
AIBP Input bridge protection board
APOW Power supply board
Connecting the control cables (page 95) Control cable connection procedure of units
with internal control unit (option +P905), page 108
BFPS Power supply board
EMC Electromagnetic compatibility
EMI Electromagnetic interference
FCAN-01 Optional CANopen adapter module
FDNA-01 Optional DeviceNet™ adapter module
FECA-01 Optional EtherCAT
FEN-01 Optional TTL encoder interface module
FEN-11 Optional absolute encoder interface module
FEN-21 Optional resolver interface module
FEN-31 Optional HTL encoder interface
FENA-11 Optional Ethernet/IP™, Modbus/TCP and PROFINET IO fieldbus adapter
module
FIO-01 Optional digital I/O extension module
FIO-11 Optional analog I/O extension module
FIO-21 Optional analog and digital I/O extension module
FLON-01 Optional LonWorks
®
adapter module
®
adapter module
FPBA-01 Optional PROFIBUS DP adapter module
Introduction to the manual
Frame (size) Size of the drive module. The drive modules described in this manual are
of frame size G1 and G2.
FSCA-01 Optional Modbus adapter
HTL High-threshold logic
IGBT Insulated gate bipolar transistor; a voltage-controlled semiconductor type
widely used in converters due to their easy controllability and high switching frequency.
I/O Input/Output
JCU The control unit of the drive module. The external I/O control signals are
connected to the JCU, or to optional I/O extension modules mounted on it.
JGDR Gate driver board
JINT Main circuit board
JMU-xx The memory unit attached to the control unit (JCU)
JRIB Adapter board connected to the control board in the control unit (JCU)
STO Safe torque off
25
SynRM Synchronous reluctance motor
RFI Radio-frequency interference
TTL
Transistor-transistor logic
Introduction to the manual
26
Introduction to the manual

Operation principle and hardware description

U1 V1
W1
U2
V2 W2
ACS850-04
R-
R+
421
5
3
UDC-
UDC+
PE

What this chapter contains

This chapter describes the operating principle and construction of the drive module in short.

Product overview

The ACS850-04 is a drive module for controlling asynchronous AC induction motors, permanent magnet motors and ABB synchronous reluctance motors (SynRM motors).
The main circuit of the drive module is shown below.
27
1 AC choke
2 Rectifier. Converts alternating current and voltage to direct current and voltage.
3 DC link. DC circuit between rectifier and inverter
4 Inverter. Converts direct current and voltage to alternating current and voltage.
5 Brake chopper (option +D150). Conducts the surplus energy from the intermediate circuit of
the drive to the brake resistor when necessary. The chopper operates when the DC link voltage exceeds certain maximum limit. The voltage rise is typically caused by deceleration (braking) of a high inertia motor.
Operation principle and hardware description
28
9
6
3
2
1
8
4
A
5
7
B
1
2
3
8
W1, V1, U1
W2, V2, U2
11
12
13
14 15
10
17
16
18

Layout

The components of the standard unit are shown below.
Item Description
A Drive module
1 Lifting lugs 2 Fastening bracket 3 Input cable connection busbars and optional DC+ and DC- busbars (+H356) 4 Circuit board compartment 5 Power supply and fiber optic cables to be connected to the external control unit 6 Output cable connection busbars and optional brake resistor connection busbars (+D150) 7 PE terminal 8 Control cable duct
9 Main cooling fans 10 Pedestal 11 Retractable support legs
Operation principle and hardware description
Item Description
12 Base fastening screws 13 Handle for pulling the drive module out of the cabinet 14 Pedestal guide plate 15 Telescopic extraction and insertion ramp 16 Top guide plate 17 Optional common mode filter (+E208) 18 Grounding busbar
B Control unit (JCU)
1 Control unit with front cover 2 Control unit with front cover removed 3 Control cable clamp plate
29
Operation principle and hardware description
30
3
1
2
3
a
A B
1
2
3
4
4
6
5
7
The drive module and optional selections are shown below: control unit and control panel variations and cabling panels.
Item Description
A Drive module
1 Input power cabling panel to be fastened to the cabinet (+H381 or +H383) 2 Output power cabling panel to be fastened to the cabinet (+H381 or +H383) 3 Front cover. With option +P905, the control panel is placed on this cover. 4 Input power cabling panel (+H381 or +H383) 5 Side guides (+H381 or +H383) 6 Output power cabling panel (+H381 or +H383) 7 Rubber grommet (+H381)
B Control unit variants
1 Control unit with control panel holder (+J414) 2 Control unit with control panel holder (+J414) when cover (a) is removed 3 Control unit with control panel (+J400) 4 Control panel door mounting kit (+J410)
Operation principle and hardware description
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