ACS800-04 and ACS800-04M Drive Modules (45 to 560 kW)

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 people who plan the electrical installation, install, commission, use and service the drive. Read the manual before working on the drive. The reader is expected to know the fundamentals of electricity, wiring, electrical componentsand

electrical schematic symbols. 

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

Special US instructions for installations within the United States that must be installed per the National Electrical Code and local codes are marked with (US). 

Categorization according to the frame size

The instructions, technical data and dimensional drawings which concern only certain frame sizes are marked with the symbol of the frame size R2, R3... or R8. 

The frame size is not marked on the drive designation label. To identify the frame size of your drive, see rating tables in chapter Technical data.

Categorization according to the plus code

The instructions, technical data and dimensional drawings which concern only certain optional selections are marked with plus codes, e.g. +E210 or +H354. The options included in the drive can be identified from the plus codes visible on the type designation label of the drive. The plus code selections are listed in chapter Operation principle and hardware description under Type code.

Contents

The chapters of this manual are briefly described below.

Safety instructions give safety instructions for the installation, commissioning, operation and maintenance of the drive.

Introduction to this manual introduces this manual.

Operation principle and hardware description describes the drive.

Mechanical installation describes the mechanical installation of the drive cabinet generally.

Planning the electrical installation instructs on the motor and cable selection, protections and cable routing.

Electrical installation instructs how to wire the drive.

Motor control and I/O board (RMIO) shows external control connections and specifications of the motor control and I/O board.

Installation checklist contains the installation checklist.

Start-up and use describes the start-up procedure and use of the drive，Maintenance contains preventive maintenance instructions.

Technical data contains the technical specifications of the drive, e.g. the ratings, sizes and technical requirements and provisions for fulfilling the requirements for CE and other markings. 

Resistor braking describes how to select, protect and wire optional brake choppers 

and resistors. The chapter also contains technical data.

Non-ABB du/dt filter selection contains guidelines on selecting and installing a nonABB du/dt filter with the drive.

RDCO-01/02/03/04 DDCS communication option modules contains a description of the RDCO-0x DDCS communication option modules connections and the technical specifications of the RDCO-0x modules.

What this chapter contains

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

ACS800-04/U4 product overview

The ACS800-04/U4 is an IP00 drive module for controlling AC motors. It is to be installed into a cabinet by the customer with base or wall fastening. The input cable terminals are located at the top of the unit whereas the motor cable terminals are located at the left- or right-hand side of the unit. The unit is delivered pre-assembled with mounting pedestal and output busbars.

Type designation label

The type designation label includes an IEC and NEMA rating, C-UL US, and CSA markings, a type code and a serial number, which allow individual recognition of each unit. The first digit of the serial number refers to the manufacturing plant. The next four digits refer to the unit’s manufacturing year and week respectively. The remaining digits complete the serial number so that there are no two units with the same serial number.

The type designation label is located on the front cover and the serial number label inside the unit. Example labels are shown below.

Type code

The type code contains information on the specifications and configuration of the drive. The first digits from left express the basic configuration (for example, ACS800-04-0170-5). The optional selections are given thereafter, separated by plus signs (for example, +E202). The main selections are described below. Not all selections are available for all types. For more information, refer to ACS800 

Ordering Information (3AFY64556568, available on request).

Printed circuit boards

The drive contains the following printed circuit boards as standard:

• main circuit board (AINT)

• motor control and I/O board (RMIO) with a fibre optic link to the AINT board

• input bridge control board (AINP)

• input bridge protection board (AIBP) which includes snubbers for the thyristors and varistors

• power supply board (APOW)

• gate driver control board (AGDR) 

• diagnostics and panel interface board (ADPI)

• brake chopper control board (ABRC) with option +D150Motor control

The motor control is based on the Direct Torque Control (DTC) method. Two phase currents and DC link voltage are measured and used for the control. The third phase current is measured for earth fault protection.

What this chapter contains

This chapter describes the mechanical installation of the drive cabinet generally. 

Follow the specific instructions given by the panel builder. For the mechanical assembly and dimensional drawings of the drive module, refer to ACS800-04/04M/U4 Cabinet Installation [3AFE68360323 (English)] and ACS800-04/04M/U4 Drive Modules (45 to 560 kW, 60 to 600 hp) Rittal TS 8 Cabinet Installation[3AFE68372330 (English)].

Unpacking the unit

The drive delivery contains:

• drive module including factory installed options such as optional modules (inserted onto the RMIO board in the RDCU control unit)

• residual voltage warning stickers

• hardware manual

• appropriate firmware manuals and guides

• appropriate optional module manuals

• delivery documents.

Note: Do not discard any important components that are in separate cardboard boxes, for example, under the drive module.

Fastening the cabinet to the floor and wall

Fasten the cabinet to the floor and wall/roof according to the panel builder’s instructions, e.g. with outside fastening brackets or by fastening holes inside the cabinet. 

Electric welding

It is not recommended to fasten the cabinet by welding.

If the preferred fastening methods (clamping or bolting through the holes inside the cabinet) cannot be used, proceed as follows:

• Connect the return conductor of the welding equipment to the cabinet frame at the bottom within 0.5 metres of the welding point.

Motor selection and compatibility

1. Select the motor according to the rating tables in chapter Technical data. Use the DriveSize PC tool if the default load cycles are not applicable.

2. Check that the motor ratings lie within the allowed ranges of the drive control program: 

• motor nominal voltage is 1/2 ... 2 · UN of the drive

• motor nominal current is 1/6 ... 2 · I2hd of the drive in DTC control and 0 ... 2 · I2hd in scalar control. The control mode is selected by a drive parameter.

3.UN = rated input voltage of the drive

UACeq1 = UDC/1.35

UACeq1 = the equivalent AC power source voltage of the drive in V AC.

UDC = the maximum DC link voltage of the drive in V DC.

For resistor braking: UDC= 1.21 × nominal DC link voltage.

Note: Nominal DC link voltage is UN × 1.35 in V DC.

See note 7 below the Requirements table, page 42.

4. Consult the motor manufacturer before using a motor in a drive system where the motor nominal voltage differs from the AC power source voltage.

5. Ensure that the motor insulation system withstands the maximum peak voltage in the motor terminals. See the Requirements table below for the required motor insulation system and drive filtering.

When the supply voltage is 440 V and a drive with a diode supply is operating in motor mode only, the maximum peak voltage in the motor terminals can be approximated as follows: 440 V · 1.35 · 2 = 1190 V. Check that the motor insulation system withstands this voltage.