Catalog ABB Industrial Drives ACS800, Drive Modules, 0.55 .
CatalogABB industrial drivesACS800, drive modules, 0.55 to 2240 kW14520 ACS800 drive modules catalog Rev H 68404592.indd 13.7.2009 10:58:30
Type code structureType codeACS800-04X041404LC-XXXX-2 XXXX357X04LC123Product seriesDrive modulesTypes and constructionsRatingsVoltagesDimensionsHardware options4Control connections and communications5Application software and programming6PC tools789Summary of features and optionsServices and supportContact and web information214520 ACS800 drive modules catalog Rev H 68404592.indd 23AFE68404592 REV H EN 3.7.20093.7.2009 10:58:38
ContentsABB industrial drives, drive modulesABB industrial drives.4Drive modules main features .6Technical specification .8Single drive modules, ACS800-04 .10Single drive modules, ACS800-14 .18Multidrive modules, ACS800 .19Liquid-cooled modules, ACS800 .27Brake options .33EMC filter.39Sine filters .40du/dt filters .42Standard user interfaceStandard I/O .44OptionsControl panel .45Optional I/O .46Fieldbus control .47Remote monitoring and diagnostics tool .48Standard control program.49Optional control programsControl solutions for different applications .50Dimensioning tool DriveSize .53Programming tool DriveAP.54Start-up and maintenance tool DriveWindow 2 .55Start-up and maintenance tool DriveWindow Light 2 .56Maintenance and integration tools DriveAnalyzer andDriveOPC .57Table.58Services .61www.abb.com/drives .623AFE68404592 REV H EN 3.7.200914520 ACS800 drive modules catalog Rev H 68404592.indd 312345678933.7.2009 10:58:39
ABB industrial drivesACS800-04X041404LCX04LC-XXXX-2357ABB industrial drivesABB industrial drives are designed for industrialapplications, and especially for applications in processindustries such as the pulp & paper, metals, mining,cement, power, chemical, and oil & gas industries.ABB industrial drives are highly flexible AC drives thatcan be configured to meet the precise needs of theseapplications, and hence order-based configuration is anintegral part of the offering. These drives cover a widerange of powers and voltages, including voltages up to690 V. ABB industrial drives come with a wide rangeof inbuilt options. A key feature of these drives isprogrammability, which makes adaptation to differentapplications easy.Industrial designABB industrial drives are designed with current ratingsto be used in industrial environments for applicationsrequiring high overloadability. The heart of the drive isDTC, Direct Torque Control, that provides high performance and significant benefits: e.g. accurate static anddynamic speed and torque control, high starting torqueand long motor cables. Inbuilt drive options make theinstallation work fast and easy.One of the most significant design criteria of ABBindustrial drives has been the long lifetime. Wearingparts such as fans and capacitors have been selectedaccordingly. Together with the extensive protectionfeatures this results in excellent reliability in thedemanding industrial market. XXXXDrive modulesDrive modules are designed to be built into acustomer’s own cabinet. The modules typically have anIP00 or IP20 enclosure class. ABB’s module packagealso includes cabinet assembly documentation.Type codeThis is the unique reference number that clearlyidentifies your drive by construction, power ratingvoltage and selected options. Using the type code youcan specify your drives from the wide range of optionsavailable, customer specific options are added to thetype code using the corresponding code.ABB’s module offering - common featuresABB industrial drive module products are meant forsystem integrators and/or OEMs who are making theirown applications, which include the cabinet structureas well as the software features needed.ACS800 modules include everything that is required fora complete drive, there is always an inbuilt harmonicfiltering choke, for example. There is also a wideselection of inbuilt options such as EMC filtering anddifferent I/O and communication options. In additionto these a selection of external accessories is alsoavailable. All the modules can be mounted side by side.In addition to the modules being designed for cabinetassembly, cabinet assembly documentation is included.The documentation gives examples of different cabinetinstallations, examples of drawings, and hints on theselection of auxiliary equipment. The flexibility andprogrammability of the modules makes them veryviable for various application needs in different areasof industry.Other productsPlease also see the separate technical cataloguesACS800 multidrives, code 3AFE68248531 EN,ACS800 single drives, code 3AFE68375126 EN.4Product series14520 ACS800 drive modules catalog Rev H 68404592.indd 43AFE68404592 REV H EN 3.7.20093.7.2009 10:58:39
ACS800-X4 single drive modulesACS800-X4 units are complete single drive moduleproducts that are optimised for assembly in customers’own cabinets.The single drive configuration contains a rectifier, DClink and an inverter in one single AC drive unit.Single driveRectifier DC linkInverterThe ACS800-X4 is designed to minimise the amount ofcabinet space used and to make cabinet assembly aseasy as possible. The power range is from 0.55 kW upto 1900 kW.ACS800-X04 multidrive modulesThe multidrive principle is based on a standard DC busarrangement enabling single power entry and commonbraking resources for several drives. There are severalpossibilities on the supply side starting from a simplediode supply unit up to highly sophisticated IGBTsupply 2 REV H EN 3.7.200914520 ACS800 drive modules catalog Rev H 68404592.indd 5The multidrive construction simplifies the totalinstallation and provides many advantages such as: savings in cabling, installation and maintenance costsspace savingsreduced component count and increased reliabilityreduced line currents and simpler brakingarrangements energy circulation over the common DC busbar, whichcan be used for motor-to-motor braking without theneed for a braking chopper or regenerative supply unit. The common supply of the multidrive enablesthe implementation of overall safety and controlfunctions.With their compact and modular design and widerange of powers, voltages and options, ABB multidrivemodules offer optimised and simple cabinet installation.The power range is from 1.1 kW up to 2000 kW.Liquid-cooled modulesThe ACS800 liquid-cooled drive modules with directliquid cooling and robust design are an ultimatesolution for various applications where space savingsand silent operation is a must.Since the coolant takes care of 98% of the heat losses,no additional filtered air-cooling is needed.This decreases the noise level and increases thetotal efficiency of the converter installation. Thehigh-efficiency liquid cooling removes the need for airconditioning in the installation rooms, bringingthe installation and operation costs down. Thepossibility to have totally enclosed cabinet structuremakes the ACS800 liquid-cooled drive modules perfectfor harsh environmental conditions.The ACS800 liquid-cooled multidrive modules areavailable from 1.1 to 2240 kW at 380 to 690V supplyvoltage while the ACS800 liquid-cooled single drivemodules from 200 kW up to 2,240 kW at 380 to 690Vsupply voltage.Product series53.7.2009 10:58:40
Drive modules main featuresFeaturesBenefitsNotesLess space and installation work required.No need to install extra components such as input chokesor EMC filter.Compact and completeCompact size, everythingintegratedPossibility for side by side mounting.Inbuilt harmonic filter in allACS800 drivesLow harmonics, meaning less interferenceand less heating in cables and transformers.Filter also protects the drive from line sidetransients.Easier installation due to lower number ofcomponents.Wide range of options availableStandard solutions available from ABB thatmeets most of the customer needs.Versatile braking optionsAlways the optimal braking option available.Brake chopper inbuilt in all frame sizes (standard/optional).In most types no need for external brakingchopper thus reducing size and installationcost.Optimised products forcabinet assemblyPossible to use any kind of customer specificcabinet.Easy to make the cabinet assembly savingtime and money.User interfaceUser-friendly customerinterfaceEasy and fast commissioning and operation.Control panel has clear, alphanumeric display with start-upassistant that guides through the start-up procedure.Easy to use PC tools available for commissioning,maintenance, monitoring and programming.Versatile connections andcommunicationsExtensive programmabilityStandard I/O covers most requirements.Extensive standard and optional I/O.Connectable to commonly used fieldbuses.I/O fulfills PELV (EN 50178).Flexibility. Possible to replace relays or evenPLC in some applications.Two levels of programmability:1. Parameter programming (standard)2. Adaptive programming (free block programming)Standard featureMore blocks available as optionsAll I/Os are programmableIndustrial designWide power and voltage range6Product series14520 ACS800 drive modules catalog Rev H 68404592.indd 6One product series suits everywhere meaningless training and fewer spare parts, and astandardised interface to drives3AFE68404592 REV H EN 3.7.20093.7.2009 10:58:40
Drive modules main featuresFeaturesBenefitsNotesSuitable for heavy industrial use.Components dimensioned for heavy duty and long lifetime.Reliable.Advanced thermal model allows high overloadability.Industrial designRobust main circuit designLong motor cables can be used withoutextra output filters.Extensive protectionsEnhanced reliability, fewer processinterruptions. Possibility to also protectmotors and process.Several adjustable limits to protect other equipment also.Galvanic isolation of I/OSafe and reliable operation without separateisolators and relays.Isolated input signals and relay outputs as standard.All terminals designed forindustrial useAdequate size even for large aluminiumcables.No need for special tools in I/O cabling.Worldwide approvals: CE, UL,cUL, CSA, C-Tick, GOST RSafe products that can be used everywhere inthe world.Right performance for every applicationDTC, accurate dynamic andstatic speed and torque controlExcellent process control even withoutpulse encoder - improved product quality,productivity, reliability and lower investmentcost.DTC - allows highoverloadability and gives highstarting torqueReliable, smooth start withoutoverdimensioning the drive.DTC, fast controlNo unnecessary trips and processinterruptions.Fast reaction to load or voltage variations prevents tripping.Rides through power interruptions by using kinetic energyof the load.DTC, flux optimization andsophisticated motor modelExcellent motor and drive efficiency - costsavings.Optimal flux in the motor reduces losses.DTC, mechanics friendlyLess stress for mechanics improves reliability.No shock torques.No torque ripple - minimized risk for torsional vibration.Active oscillation damping.Both positioning / synchronizingcontrol and normal speed /torque control available in thesame hardwareSame hardware and similar user interface fordifferent applications meaning less trainingand fewer spare parts as well as easiersystem design and documentation.Made in ABBGlobal market leader inAC drives. Long experience.Well proven, safe and reliable solutions.Application know-how.World wide service and supportnetworkProfessional support available around theworld.3AFE68404592 REV H EN 3.7.200914520 ACS800 drive modules catalog Rev H 68404592.indd 7Product series73.7.2009 10:58:40
Technical specificationACS800-04X0414-XXXX-2357 XXXXMains connectionEnvironmental limitsVoltage andpower rangeAmbient encyPower factor3-phase, U2IN 208 to 240 V, 10%,except multidrive and nxR8i ACS800-04modules3-phase, U3IN 380 to 415 V, 10%3-phase, U5IN 380 to 500 V, 10%3-phase, U7IN 525 to 690 V, 10%48 to 63 Hzcosϕ1 0.98 (fundamental)cosϕ 0.93 to 0.95 (total)Power factorISUcosϕ1 1 (fundamental)cosϕ 0.99 (total)Efficiency (at nominal power)ACS800-0498%ACS800-X0498%97% with IGBT supply unitACS800-04 nxR8i,X04, 14Cooling method:Altitude0.1000 m1000.4000 mRelative humidity-40 to 70 C-40 to 70 C-15 to 50 C, no frost allowed40 to 50 C at reduced output current(1% / 1 C)0 to 50 C, no frost allowed40 to 50 C at reduced output current(1% / 1 C)Dry clean airwithout deratingwith derating (1% / 100 m)(690 V units 1000 to 2000 m with derating)5 to 95%, no condensation allowedMotors connectionProtection classVoltagefor 500 V unitsIP00standard for -04 and 04(M) frame sizes R7,R8 and nxR8iIP20Standard for -04 frame sizes R2-R6 andoption for some -04(M) variantsPaint colourNCS 1502-Y(RAL 9002, PMS 420 C)Contamination levelsNo conductive dust allowedStorageIEC 60721-3-1, class 1C2 (chemical gases),Class 1S2 (solid particles)TransportationIEC 60721-3-2, Class 2C2 or 3C2* (chemicalgases), Class 2S2 (solid particles)OperationIEC 60721-3-3, Class 3C2 (chemical gases),Class 3S2 (solid particles without airinletfilters)3-phase output voltage 0 to U2IN//U3IN//U5IN//U7INplease see “Filter selection table forACS800” under the du/dt filters on page 34Frequency0 to 300 Hz0 to 300Hz, also with inbuilt du/dt filters inR8i module.(0 to 120Hz with external du/dt filters inR2i-R7i)Field weakening point 8 to 300 HzMotor controlABB’s Direct Torque Control (DTC)Torque control:Open loopClosed loopTorque step rise time: 5 ms with nominal torque 5 ms with nominal torqueNon-linearity: 4% with nominal torque 3% with nominal torqueOpen loopClosed loopSpeed control:Open loopClosed loopOpen loopClosed loopStatic accuracy:10% of motor slip0.01% of nominal speedDynamic accuracy:0.3 to 0.4%sec. with 100% torque step0.1 to 0.2%sec. with 100% torque stepC chemically active substancesS mechanically active substances* coated circuit boardsProduct complianceCE, UL, cUL, CSA; C-Tick and GOST RLow Voltage Directive 73/23/EEC with amendment 93/68/EECMachinery Directive 98/37/ECEMC Directive 89/336/EEC with amendment 93/68/EECQuality assurance system ISO 9001 andEnvironmental system ISO 14001EMC according to EN 61800-32nd environment, unrestricted distribution category C3 - as option inACS800-04 up to frame size R81st environment, restricted distribution category C2 as option up to1000 A input currentAvailable options are shown in the Summary of features and optionstable. Please see pages 58-59.8Product seriesACS800d EN revH 68404592.indd 83AFE68404592 REV H EN 3.7.20098.7.2009 10:43:00
Technical specificationACS800-04LCX04LC-XXXX-357Mains connection3-Phase Supply VoltageFrequencyPower factorEfficiency(at nominal power)Open loopClosed loopSpeed Control:Open loopClosed loopOpen loopClosed loop 98%Output voltage: 0.U3IN /U5IN/U7IN0 to 300 Hz8 to 300 HzABB’s Direct Torque Control (DTC)Torque step rise time: 5 ms with nominal torque 5 ms with nominal torqueNon-linearity: 4% with nominal torque 1% with nominal torqueStatic accuracy:10% of motor slip0.01% of nominal speedDynamic accuracy:0.3 to 0.4%sec. with 100% torquestep0.1 to 0.2%sec. with 100% torquestepEnclosureIP classPaint color module frontXXXXEnvironmental limits3-phase U3IN 380 to 415 V, 10%3-phase U5IN 380 to 500 V, 10%3-phase U7IN 525 to 690 V, 10%48 to 63 Hzcosϕ1 0.98 (fundamental),cosϕ 0.93 to 0.95 (total)Motor connection3-phase supply voltageFrequency controlField weakening pointMotor control softwareTorque control:Open loopClosed loop IP00Light beige RAL 7035Ambient temperatureTransportationStorageOperation in totally enclosedcabinet-40 to 70 C-40 to 70 C0 to 45 C, no frost allowed45 to 55 C at reduced output power(0,5% /1 C)Relative humidity5 to 95%, no condensation allowedVibration0.7 g, 13.2 Hz to 100 Hz, 1 mmdisplacement 2 to 13.2 HzCooling MethodLiquid-cooled, closed loopInternal cooling circuitDrinking water 42 C max,42 to 48 C at reduced output power(1.0%/1 C)External cooling circuitIndustrial or sea water 38 Cwith optimal liquid cooling unit max, 38 to 45 C at reduced outputpower (1.0%/1 C)Altitude0 to 2000 m without derating, 2000 to4000 m with deratingStorageIEC 60721-3-1, class 1C2 (chemicalgases), Class 1S2 (solid particles)TransportationIEC 60721-3-2, Class 2C2 or 3C2*(chemical gases), Class 2S2 (solidparticles)OperationIEC 60721-3-3, Class 3C2 (chemicalgases), Class 3S2 (solid particleswithout air inlet filters)C chemically active substancesS mechanically active substances* coated circuit boardsProduct complianceCE, UL, CSA, GOST-RLow Voltage Directive 73/23/EEC with amendment 93/68/EECMachinery Directive 98/37/ECEMC Directive 89/336/EEC with amendment 93/68/EECQuality assurance system ISO 9001 and Environmental systemISO 14001EMC according to EN 61800-32nd environment, unrestricted distribution category C3 - as option inACS800-04 up to frame size R81st environment, restricted distribution category C2 as option up to1000 A input current3AFE68404592 REV H EN 3.7.2009ACS800d EN revH 68404592.indd 9Product series98.7.2009 10:43:01
Single drive modulesACS800-04/-04MACS800-04 single drive modulesACS800-04 drives are single drive modules that areoptimised for building into customers’ own cabinets.They have been designed to minimise the cabinet spaceused, make cabinet assembly as easy as possible, andgive maximum flexibility. The power range is from0.55 kW up to 1900 kW. All the drives, regardless of thepower and voltage, have the same customer interfaceand I/O making system design and training easier.The units have everything necessary inbuilt. Thatincludes, for example, inbuilt chokes for harmonicfiltering as standard, inbuilt braking chopper and inbuiltEMC filtering (both are optional in some frame sizes),making cabinet assembly easier. There is also a wideselection of different I/O and communications options.In addition to these there is a selection of externalaccessories available.To optimise the use of the cabinet space, most of theACS800-04 modules can be mounted side by side.The modules themselves are not only designed forcabinet assembly, but covering documentation is alsoavailable. This documentation provides examples ofdifferent cabinet installations and circuit drawings, andhints on the selection of auxiliary equipment.Optimised for cabinet assembly frame sizes R2 - R6The R2 - R6 frame size units are designed for cabinetwall mounting. The power range starts from 0.55 kW andextends up to 200 kW. The voltage range is from 230 Vup to 690 V. The enclosure class of the modules is IP20as standard.Compact power - frame sizes R7 and R8Frame size R7 and R8 modules have a very narrowbookshelf design. They are designed to be mountedeither on the cabinet wall or floor. The power rangeis from 45 kW up to 560 kW and the voltage range
ABB industrial drives ACS800, drive modules, 0.55 to 2240 kW Catalog 114520 ACS800 drive modules catalog Rev H_68404592.indd 14520 ACS800 drive modules catalog Rev H_68404592.indd 1 33.7.2009 10:58:30.7.2009 10:58:30
Catalog ABB industrial drives ACS800 multidrives 3 Contents ABB industrial drives, ACS800, multidrives ABB industrial drives 4 Multidrive main features 8 Technical data 11 Drive and supply units 400, 500 and 690 V 12 ACS800 liquid-cooled multidrives 18 Drive and supply units 400, 500 and 690 V 19 Brake options 25 3-phase high power brake units 26
ACS800-01/U1 Hardware Manual 3AFE64382101 ACS800-04/04M/U4 Hardware Manual (45 to 560 kW) 3AFE64671006 ACS800-04 Drive Modules Hardware Manual (0.55 to 200 kW) 3AFE68372984 ACS800-11/U11 Hardware Manual 3AFE68367883 ACS800-14 Frequency Converter Modules Supplement 3AFE68458986 ACS800-31/U31 Hardware Manual 3AFE64671006
ACS800 Centrifuge Control Program Supplement 3AFE64667246 ACS800 Traverse Control Program Supplement 3AFE64618334 ACS800 Winch Control Program ( N698) Firmware Manual 3AUA0000031177 ACS800 Rod Pump Light Control Program Firmware Manual 3AUA0000005304 etc. Option manuals and guides ACS800-01/U1/04 C132 Drives (0.55 to 200 kW, 0.75 to 200
ABB industrial drive - cabinet drives Other ABB industrial drives variants Drive type ACS55 ACS150 ACS355 ACSM1 ACS550 ACS310 ACQ810 ACS800 - 01/11/ 31 ACS800 - 02/04/14. ACS850 ACS800 - 07/17/37 ACS800 - various 110-120V 1ph 208-240V 3ph 200-240V 1ph 380-480V 3ph 208-240V 3ph 380-415V 3ph 380-480V 3ph 500V 3ph
speed feedback when the ACS800 with DTC is used. IndustrialIT enabled ABB industrial drives are IndustrialIT enabled. This guar-antees the user that ABB industrial drives can be easily integrated into ABB Industrial IT systems. Single drives The single drive configuration contains a rectifier, DC link and an inverter in one single AC drive unit.
HARDWARE MANUALS (appropriate manual is included in the delivery) ACS800-01/U1 Hardware Manual 0.55 to 110 kW (0.75 to 150 HP) 3AFE64382101 (English) ACS800-01/U1 Marine Supplement 3AFE64291275 (English) ACS800-02/U2 Hardware Manual 90 to 500 kW (125 to 600 HP) 3AFE64567373 (English) ACS800-11/U11 Hardware Manual 5.5 to110 kW (7.5 to 125 HP)
ABB industrial drives ACS800, single drives ACS800, regenerative AC drives ACS800, ultra low harmonic drives Technical catalog 0.75 to 75 HP @ 240 Vac 2 to 2250 HP @ 480 Vac 5 to 3000 HP @ 600 Vac BUSINESS PROFILE INDUSTRIES APPLICATIONS EXPERTISE PARTNERS PRODUCTS SERVICES
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