ABB ACS800 inverter IGBT module



ABB ACS800 inverter IGBT module

Safety Notice

Applicable products: Suitable for ACS800-01/U1 and ACS800-02/U2 products.

Warning and Caution

Warning: Remind of situations that may cause serious injury or death and/or damage to equipment, such as dangerous voltage, electrostatic discharge, etc.

Attention: Remind users of special situations or events, or introduce relevant information on the topic, such as dangerous high voltage at motor cable terminals.

Installation and maintenance work

Only qualified electrical engineers are allowed to install and maintain transmission units.

It is prohibited to install or repair transmission units, motor cables or motors with electricity. After cutting off the input power, wait for at least 5 minutes until the intermediate circuit capacitor is discharged, and use a multimeter to measure and confirm the discharge before operation.

Do not operate control cables when the transmission unit or external control circuit is energized.

All insulation tests must be conducted with the cable disconnected, and ensure the correct phase sequence when reconnecting the cable.

grounding

Proper grounding is necessary to ensure the safety of personnel, reduce electromagnetic radiation and interference. The cross-sectional area of the grounding wire must meet safety regulations, and multiple equipment grounding terminals cannot be connected in series.

In scenarios that comply with European CE standards, cable entrances should maintain a 360 degree high-frequency grounding, and the cable shielding layer should be connected to the protective grounding wire (PE).

Do not install frequency converters with EMC filters in floating or high ground resistance power systems.

Mechanical Installation

The transmission unit is heavy and should not be carried by a single person. When carrying, do not let the front panel bear the weight and rely on lifting the back for transportation.

Ensure that drilling debris does not enter the transmission unit during installation, ensure sufficient cooling space, and do not fix the transmission unit by riveting or welding.

operate

Before debugging the transmission unit, ensure that the motor and driven equipment are suitable for operation within the speed range provided by the transmission unit.

Do not activate the automatic fault reset function of standard applications in situations where danger may occur.

Do not use the main power circuit breaker to control the start and stop of the motor. Instead, use control commands from the control panel keys or transmission unit I/O board.

Permanent magnet motor

When ACS800 is used to drive permanent magnet motors, only scalar control mode can be used.

When the permanent magnet motor is running, do not operate the transmission unit, as its operation transfers electrical energy back to the intermediate circuit. Even if the inverter is not working, the power supply will still charge the transmission system.

During installation and maintenance, use a fuse switch to disconnect the motor from the transmission unit. If possible, lock the motor shaft, connect the motor connection terminals together, and ground them.

Do not operate the permanent magnet motor at speeds higher than the rated speed to avoid overvoltage and capacitor bank rupture.

Product Overview

ACS800-01/U1: A wall mounted transmission unit used to control low-voltage AC asynchronous motors, with different external specifications (R2~R6), protection levels including IP21 (NEMA1) and IP55 (NEMA4, indoor only), etc. The control panel is CDP312R, including printed circuit boards such as main circuit board (RINT), motor control and I/O control board (RMIO), etc. The motor control mode can choose direct torque control (DTC) or scalar control.

ACS800-02/U2: There is relatively little mention in the document, and the external specifications are R7 and R8. Other information can refer to the relevant content of ACS800-01/U1. Some chapters of the two are common, such as safety instructions, electrical installation design, and braking resistors.

Installation

Mechanical Installation

Unpacking and inspection: After unpacking, check for any damage to the appearance, verify if the nameplate of the frequency converter matches the order, and check if the optional modules and equipment are complete.

Preparation before installation: Install vertically, place the radiator against the wall, check if the walls and floors of the installation site meet the requirements, ensure that there is enough space around the transmission unit for cooling air circulation, facilitate maintenance and repair, and pay attention to the space requirements when placing equipment of different protection levels up and down.

Installation method: including wall mounted installation and cabinet installation. Wall mounted installation requires marking the installation hole position with a punching template, fixing screws or bolts, installing the transmission unit and tightening it; Attention should be paid to the horizontal installation distance between the frequency converters when installing inside the cabinet, to prevent the recirculation of cooling air, and to set up air baffles.

Electrical installation design

Motor compatibility check: Ensure that the rated voltage and current of the motor meet the requirements, and avoid the rated voltage of the motor being less than 1/2 of the rated input voltage of the transmission unit or the rated current being less than 1/6 of the rated output current of the transmission unit.

Protecting motor windings and bearings: The output pulse voltage of the transmission unit may affect the motor insulation and bearings. ABB du/dt filters, common mode filters, etc. can be used to reduce the impact. Suitable filters and insulated bearings should be selected according to the motor type and power.

Power supply system connection: A manually operated circuit breaker can be installed between the AC power supply and the transmission unit, which must comply with relevant standards, such as using category AC-23B, etc; The input cable needs to be equipped with a fuse group, and the fuse model should be selected according to local safety regulations, input voltage, and rated current of the transmission unit.

Cable selection and wiring: The main power and motor cables need to be selected according to local regulations to meet the requirements of load current and temperature. The protection ground cables need to consider inductance and impedance limitations; It is best to use shielded cables for control cables, with separate routing for analog and digital signals to avoid long-distance parallel routing. When crossing, the angle should be 90 degrees.

electrical installation

Insulation performance inspection: Check the insulation performance of the motor and motor cables, disconnect the transmission unit from the main power supply, use a 1kV insulation meter to measure the insulation resistance of each relative protective ground, and the resistance value should be greater than 1 megohm.

Power cable wiring: Determine the length of wire stripping according to the external specifications, ground the cable shielding layer, connect the main power cable and motor cable to the corresponding terminals, and fix the junction box cover and front cover.

Control cable wiring: Thread the control cable through the entrance hole and connect it to the relevant detachable terminals on the RMIO board, ensuring a secure connection, grounding the shielding layer, and fixing the control cable and front cover.

Maintenance

Maintenance Cycle

Capacitor update: once a year when stored.

Temperature inspection and cleaning of radiator: Depending on the dust content in the environment, it should be done every 6-12 months.

Cooling fan replacement: Replace every five years, and replace spare fans for IP55 units and some IP21 units every three years.

Maintain content

Cleaning of radiator: Remove the cooling fan, use clean and dry compressed air to blow the radiator from bottom to top, while using a vacuum cleaner to absorb dust at the air outlet, and then install the cooling fan.

Cooling fan inspection: Pay attention to the noise of the fan bearings and the temperature of the radiator. Replace them in a timely manner when signs of damage appear, and use ABB designated spare parts.

Capacitor inspection: Electrolytic capacitors are used in the intermediate circuit, with a service life of about 100000 hours. Damage is often accompanied by the main power fuse melting or fault tripping. If there is suspicion of damage, contact the ABB representative office and use designated spare parts.

LED indication: The LED lights on the RMIO board and control panel installation components can indicate faults and normal power status.

Technical data

IEC level: lists the rated capacity, external specifications, air flow rate, heat loss, and other data of different models of ACS800-01 under 50Hz and 60Hz grid power supply.

Capacity reduction

Temperature induced capacity reduction: When the ambient temperature is between+40 ° C and 50 ° C, for every 1 ° C increase, the rated output current decreases by 1%. The rated current Icont.max is not allowed to be applied in environments exceeding 40 ° C.

Capacity reduction caused by altitude: When the altitude is between 1000-4000m, the rated current decreases by 1% for every 100m increase. If it exceeds 2000m, consult the local ABB dealer or office.

Main power cable fuse: provides cable specifications, fuse models, parameters, etc. corresponding to different models of ACS800-01.

Cable entry hole: information such as terminal size, cable diameter, and tightening torque for different external specifications.

Size, weight, and noise: The size, weight, and noise data of each external specification under different protection levels.

Motor wiring: parameters such as voltage, frequency, current, power limit, and recommended maximum motor cable length.

Efficiency and cooling: The efficiency is approximately 98% of the rated power, and the cooling method is an internal fan with a flow direction from the bottom to the top.

Protection level and environmental conditions: Protection levels include IP21 and IP55, as well as operating conditions such as environmental temperature, relative humidity, and pollution level.

Materials and applicable standards: Information on materials such as transmission unit casing and packaging boxes, following international standards such as EN50178, EN60204-1, etc.

Braking resistor

Configuration and selection: Transmission units with external specifications of R2 and R3 include built-in brake choppers, R4 and larger brake choppers are optional (model+D150), and resistors are additional components; When selecting the transmission unit/chopper/resistor, it is necessary to calculate the braking power to ensure that the resistor resistance and heat loss capacity meet the requirements.

Installation and wiring: All resistors must be installed outside the transmission unit module, with flame-retardant materials nearby. They should be connected using cables of the same model as the input cables of the transmission unit, with a maximum allowable length of 10m. The shielding layer should be properly grounded.

Protection and debugging: It is recommended to configure the main circuit contactor for external specifications R2~R5, and whether R6, R7, and R8 are needed depends on the selection situation; A thermal switch should be installed inside the braking resistor and connected to the digital input port as an external fault interlock signal; Activate the brake chopper function during debugging, turn off the overvoltage control function, and check the resistance value setting.

Model Supplement

IGBT MODULE KIT FS450R12KE3/AGDR-61C S 64635875

IGBT MODULE KIT FS300R17KE3/AGDR-66C S 64717839

IGBT MODULE KIT FS300R12KE3/AGDR-62C S 64717812

IGBT MODULE KIT FS450R17KE3/AGDR-61C S 64783831

IGBT MODULE KIT FS225R12KE3/AGDR-71C S 68569303

IGBT MODULE KIT FS300R12KE3/AGDR-72C S 68569541

IGBT MODULE KIT FS450R12KE3/AGDR-71C S 68569354

IGBT MODULE KIT FS225R17KE3/AGDR-76C S 68569583

IGBT MODULE KIT FS300R17KE3/AGDR-76C S 68569362

IGBT MODULE KIT FS450R17KE3/AGDR-71C S 68569591

IGBT MODULE KIT FS450R17KE3/AGDR-72C S 68569427

IGBT MODULE KIT FS300R12KE3/AGDR-71C S 68569346

IGBT MODULE KIT FS450R17OE4/AGDR-71C S TIM FOIL SP 3AXD50000948185