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

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.

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.

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.

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)

Unpack and check the units.

Check that all necessary optional modules and

equipment are present and correct.

Only intact units may be started up.

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)

Operation principle and hardware description

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.