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Welcome to the Planning the installation training module for the ACS850-04, ABB machinery drive modules.

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After completing this module, you will be able to describe the environmental limits of the drive, dimensions of the drive modules, requirements for the cabinet construction, the delivery check for the contents of the drive package, drive identification using the type and software designation labels, the necessary protective devices for the drive, and the correct cabling rules for the power and control cable connections.

You will also be able to locate support material that will guide you during the installation process.

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The ACS850-04 drive is to be used in a heated, indoor, controlled environment.

The installation site should meet the following ambient conditions:

The maximum allowed installation altitude is 4000 m above sea level, derating is required above 1000 m.

The air temperature range is between -10 and +55 °C, derating is required above 40 °C and no frost is allowed.

The maximum allowed relative humidity is 95 %. No condensation is allowed. In the presence of corrosive gases the maximum allowed relative humidity is reduced to 60 %.

Contamination levels are according to the IEC standard, class 3C2 for chemical gases and class 3S2 for solid particles.

Cooling air must be clean, free from corrosive materials and electrically conductive dust.

Vibration endurance is tested according to the IEC standard, mechanical conditions class 3M4.

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Example dimensions of the drive modules are listed here.

The required free space for the ventilation openings for frame sizes A to E0 is 200 mm above and 300 mm below the drive.

Free space requirements for G, G1 and G2 frames drives depend on the cabinet construction and are described in the hardware manual.

No free space is required on the sides, so the drives can be mounted side by side.

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The drive may be equipped with internal and external options.

The extra space require for the options needs to be taken into consideration when planning the installation.

The ACS850-04 control unit has three slots for internal options.

Internal options are installed inside the front cover and do not increase drive dimensions.

External options such as mains chokes, mains filters and braking resistors are normally installed inside the cabinet close to the drive modules.

For specific dimensional drawings of each external option please refer to the hardware manuals.

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The ACS850-04 frame sizes A-E are IP20 (UL open type) drive modules and are designed for cabinet mounting.

For G, G1 and G2 frames the protection class is IP00 (UL open type) to IP20 depending on installation design.

There are certain requirements for the cabinet construction:

The cabinet wall should be as close to vertical and even as possible, made of non-flammable material, and strong enough to carry the weight of the drive.

The floor or material below the installation should be non-flammable.

All drive system components must be properly grounded and the connecting surfaces left unpainted.

The cabinet must provide sufficient free space for obligatory clearances, cooling air flow and cables.

Air inlets and outlets must be equipped with gratings that guide the air flow, protect against contact and prevent dust and water splashes from entering the cabinet.

The cabinet construction must prevent recirculation of hot air both inside and outside the cabinet.

Furthermore, the cabinet design must adhere to local laws and regulations.

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Category C2 EMC compliance under the European EMC Directive requires that the motor cable shields have 360 degree high frequency groundings at their cabinet entries.

The grounding can be done with a wire mesh shielding as shown here.

360 degree groundings are also recommended for the control cable entries.

The groundings significantly reduce interference.

Generally, the smaller the holes in the cabinet, and the fewer of them there are, the better the interference attenuation.

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It should be noted that the importance of a good cabinet design is often understated, and that a bad cabinet design can compromise the product reliability.

When planning the cabinet assembly please pay attention especially to:

Size and location of the air inlets and outlets. Badly sized or positioned inlets or outlets will cause temperature rise inside the cabinet which may lead to wearing of components as well as unexpected behavior of the drive.

Prevention of the hot air circulation inside cabinet is also very important for keeping the cooling air temperature within the specified limits.

Also ensure that all the drive system components are properly grounded through their fastening points to the installation base.

While cabinet design is always important it is good to remember that it becomes even more crucial when the drive nominal power increases.

The larger the drive, the more attention has to be paid to the cabinet design.

The drive is delivered in a cardboard or plywood box which includes:

•The drive with a power unit, a control unit and a memory unit and in some cases internal and external options,

•a multilingual quick installation guide,

•one control cable clamping plate with screws, and a set of removable control connectors.

•Two power cable clamping plates with screws are included for frame sizes A through D, and four removable power connectors for frame sizes A and B.

Please check that the delivered components do not show any signs of damage.

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The ACS850-04 type designation label is attached to the metal frame of the drive. Here is an example.

The type code is located on the top and includes information on:

The product series,

the product type,

the size (current rating) of the unit, and the nominal supply voltage range,

a plus sign (+) separates the possible option codes from the main type code part.

Other information on the type designation label include:

The degree of protection on the left, right below the ABB logo,

the frame size,

nominal ratings of the drive in the middle,

the serial number of the drive below the bar code, and

the compliance markings.

Please check the information on the type designation label to verify that the unit is of the correct type.

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The ACS850-04 software designation label is attached to the memory unit.

The software code is located on the top and includes information on:

The product series,

the product type, and

the memory unit hardware version.

Other information on the software designation label include:

The firmware version,

possible solution program, technology library and technology extension options,

and the serial number of the memory unit.

Please check the information on the software designation label to verify that the software is of the correct type.

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The following general instructions should be followed when selecting protections for the drive:

A hand-operated supply disconnecting device should be installed between the power source and the drive. The disconnecting device must be of a type that can be locked to the open position for installation and maintenance work. The drive protects itself and the input and motor cables against thermal overload and short-circuits in the motor cable.

The supply cable should always be protected with fuses or circuit breakers. The rating tables for the supply cable fuses can be found in the hardware manuals.

The drive includes a motor thermal protection function which monitors either a calculated temperature value or an actual temperature indication given by motor temperature sensors.

The drive is also equipped with an internal ground fault protective function. This function however only protects the drive against ground faults in the motor and the motor cable and is not a personal safety or a fire protection feature.

For safety reasons, emergency stop devices should be installed at each operator control station.

The drive supports the safe torque off function which can be used to disable the control voltage of the output stage semiconductors.

The drive also supports various programmable fault functions. The use of these functions is instructed in the firmware manual.

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When selecting the supply and motor cables please follow these general instructions:

The cables must be able to carry the drive load current.

It should be noted that the cables must also be able to carry a high enough short circuit current to cause the supply cable fuses to open in a fault situation.

The conductivity of the PE conductor must be equal to that of a phase conductor.

A symmetrical shielded motor cable must be used to meet the EMC requirements of the CE and C-tick marks. The motor cable should be kept as short as possible in order to reduce electromagnetic emission.

A four-conductor system is allowed for AC supply cabling, but a shielded symmetrical cable is recommended.

Compared to a four-conductor system, the use of a symmetrical shielded cable reduces electromagnetic emission of the whole drive system as well as motor bearing currents and wear.

Two-conductor systems with a separate PE conductor may also be used with the DC supply and braking resistor cabling.

However, symmetrical shielded cables are again recommended.

Also, the cable selections must always be made according to applicable local laws and regulations.

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It is recommended that all control cables be shielded.

For analogue signals a double-shielded twisted pair cable is recommended.

Also for low-voltage digital signals the double-shielded cable is the best alternative but a single-shielded twisted multipair cable is also usable.

The analogue and digital signals should be run in separate cables.

Relay-controlled signals can be run in the same cables as digital input signals, provided that their voltage does not exceed 48 V.

It’s recommended that the relay-controlled signals be run as twisted pairs.

For pulse encoder cabling, follow the instructions given by the encoder manufacturer.

When a control panel is used, the cable connecting the control panel to the drive must not exceed 3 meters in length.

The cable type tested and approved by ABB is used in control panel option kits.

Never mix 24 VDC and 115/230 VAC signals in the same cable and never use a common return for different analogue signals.

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When planning the power cable and control cable routing, please follow these guidelines:

Route the control cables away from the power cables.

Where control cables must cross power cables make sure they are arranged at an angle as near to 90 degrees as possible.

Route the motor cable away from other cable routes.

The motor cables of several drives can be run in parallel, installed next to each other.

It’s recommended that the motor cable, input power cable and control cables be installed on separate trays.

Avoid long parallel runs of motor cables with other cables in order to decrease electromagnetic interference caused by the rapid changes in the drive output voltage.

The cable trays must have good electrical bonding to each other and to the grounding electrodes.

Aluminum tray systems can be used to improve local equalizing of potential.

Lead 24 V and 230 V control cables in separate ducts inside the cabinet.

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Public support material such as manuals and brochures is available in the ABB drives document library.

The drive PC tools offer several software tools to ease and enhance the use of ABB drives.

The ABB service guide provides a full range of lifecycle services from spare parts and equipment repair to training, migration, remote monitoring and technical support.

Parts OnLine is a spare parts information and ordering system from ABB.

See also the Drive services portal for information on the ABB drives service concept.

Internal support material is available in the ABB in-house maintenance manual.

In problem situations, please contact your local ABB representative.

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For more information on planning the installation please see the ACS850-04 manuals that are available online. When planning the protections for the drive please refer to the standard control program firmware manual.

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Thank you for viewing this presentation. You may now move on to the next unit.