ABB ACQ810-04 User manual

ABB industrial drives
Hardware manual
ACQ810-04 drive modules (1.1…45 kW, 1…60 hp)

List of related manuals
1) Delivered in PDF format on a manuals CD with the drive module.
2) Delivered as a printed copy with the drive or optional equipment.
All manuals are available in PDF format on the Internet. See section Document library
on the Internet on the inside of the back cover.
Drive hardware manuals and guides Code (English)
ACQ810-04 drive modules (1.1…45 kW, 1…60 hp)
hardware manual
3AUA0000055160 1)
Drive firmware manuals and guides
ACQ810-04 drive modules start-up guide 3AUA0000055159 2)
ACQ810 standard pump control program
firmware manual
3AUA0000055144 1)
Option manuals and guides
ACS-CP-U control panel IP54 mounting platform kit
(+J410) installation guide
3AUA0000049072 2)
Manuals and quick guides for I/O extension modules,
fieldbus adapters, etc.
2)

Hardware manual
ACQ810-04 drive modules (1.1…45 kW,
1…60 hp)
3AUA0000055160 Rev A
EN
EFFECTIVE: 2009-09-18
©2009 ABB Oy. All Rights Reserved.
1. Safety instructions
Table of contents
5. Mechanical installation
7. Electrical installation

Safety instructions 5
Safety instructions
What this chapter contains
This chapter contains the safety instructions which you must follow when installing,
operating and servicing the drive. If ignored, physical injury or death may follow, or
damage may occur to the drive, the motor, or driven equipment. Read the safety
instructions before you work on the unit.
Use of warnings and notes
There are four types of safety instructions used in this manual:
Dangerous voltage warning warns of high voltage which can cause physical injury
and/or damage to the equipment.
General warning warns about conditions, other than those caused by electricity,
which can result in physical injury and/or damage to the equipment.
Electrostatic discharge warning warns of electrostatic discharge which can
damage the equipment.
Hot surface warning warns of component surfaces that may become hot enough
to cause burns if touched.

6 Safety instructions
Installation and maintenance work
These warnings are intended for all who work on the drive, motor cable or motor.
WARNING! Ignoring the following instructions can cause physical injury or death, or
damage to the equipment.
Only qualified electricians are allowed to install and maintain the drive.
•Never work on the drive, the motor cable or the motor when input power is applied. After
disconnecting the input power, always wait for 5 minutes to let the intermediate circuit
capacitors discharge before you start working on the drive, the motor or the motor cable.
Always ensure by measuring with a multimeter (impedance at least 1 Mohm) that:
1. There is no voltage between the drive input phases U1, V1 and W1 and the ground.
2. There is no voltage between terminals UDC+ and UDC– and the ground.
3. There is no voltage between terminals R+ and R– and the ground.
•Do not work on the control cables when power is applied to the drive or to the external
control circuits. Externally supplied control circuits may carry dangerous voltages even
when the input power of the drive is switched off.
•Do not make any insulation or voltage withstand tests on the drive.
•If a drive whose varistors or internal EMC filters are not disconnected is installed on an IT
power system (an ungrounded power system or a high resistance grounded [over 30
ohms] power system), the drive will be connected to earth potential through the varistors/
filters. This may cause danger or damage the drive.
•If a drive whose varistors or internal EMC filter are not disconnected is installed on a
corner-grounded TN system, the drive will be damaged.
Notes:
•Even when the motor is stopped, dangerous voltages are present at the power circuit
terminals U1, V1, W1 and U2, V2, W2, and UDC+, UDC–, R+, R–.
•Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V) may be
present on the terminals of the relay outputs of the drive.
•The drive supports the Safe torque off function. See page 40.
WARNING! Ignoring the following instructions can cause physical injury or death, or
damage to the equipment.
•The drive is not field repairable. Never attempt to repair a malfunctioning drive; contact
your local ABB representative or Authorized Service Center.
•Make sure that dust from drilling does not enter the drive during the installation.
Electrically conductive dust inside the drive may cause damage or lead to malfunction.

Safety instructions 7
Start-up and operation
These warnings are intended for all who plan the operation of the drive, start up or
operate the drive.
•Ensure sufficient cooling.
WARNING! The printed circuit boards contain components sensitive to electrostatic
discharge. Wear a grounding wrist band when handling the boards. Do not touch the
boards unnecessarily.
WARNING! Ignoring the following instructions can cause physical injury or death, or
damage to the equipment.
•Before adjusting the drive and putting it into service, make sure that the motor and all
driven equipment are suitable for operation throughout the speed range provided by the
drive. The drive can be adjusted to operate the motor at speeds above and below the
speed provided by connecting the motor directly to the power line.
•Do not activate automatic fault reset functions if dangerous situations can occur. When
activated, these functions will reset the drive and resume operation after a fault.
•Do not control the motor with an AC contactor or disconnecting device (disconnecting
means); instead, use the control panel or external commands via the I/O board of the
drive or a fieldbus adapter. The maximum allowed number of charging cycles of the DC
capacitors (i.e. power-ups by applying power) is one per two minutes. The maximum total
number of chargings is 100000 for frame sizes A and B, 50000 for frame sizes C and D.
Notes:
•If an external source for start command is selected and it is ON, the drive will start
immediately after an input voltage break or a fault reset unless the drive is configured for
3-wire (pulse) start/stop.
•When the control location is not set to local, the stop key on the control panel will not stop
the drive.
WARNING! The surfaces of drive system components (such as the mains choke)
may become hot when the system is in use.

8 Safety instructions

Table of contents 9
Table of contents
List of related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1. Safety instructions
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Start-up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2. About this manual
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Categorization according to the frame size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Categorization according to the + code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation and commissioning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3. Operation principle and hardware description
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
The ACQ810-04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Main circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Power connections and control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Type designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4. Planning the cabinet assembly
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Cabinet construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Disposition of the devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Grounding of mounting structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Planning the fastening of the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Main dimensions and free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Cooling and degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Preventing the recirculation of hot air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Cabinet heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5. Mechanical installation
Contents of the package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Delivery check and drive module identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

10 Table of contents
Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Direct wall mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DIN rail mounting (Frames A and B only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Mains choke installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
EMC filter installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6. Planning the electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Motor selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Supply connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Other regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Thermal overload and short circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Thermal overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Protection against short-circuit in motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Protection against short-circuit in the supply cable or the drive . . . . . . . . . . . . . . . . . . . . 38
Motor thermal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Ground fault protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Emergency stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Safe torque off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Implementing a bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Protecting the relay output contacts and attenuating disturbances in case of inductive loads 44
Considering the PELV requirements at sites above 2000 m (6562 ft) . . . . . . . . . . . . . . . . . . 44
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Connection of a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7. Electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Removing the cover assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Supply cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Power cable connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Power cable connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Connecting a PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Installation of optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Table of contents 11
Electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Control connections to the JCU Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Grounding and routing the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
8. Installation checklist
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
9. Maintenance
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Fan replacement (Frames A and B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Fan replacement (Frames C and D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Other maintenance actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Transferring the memory unit to a new drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
10. Technical data
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Cooling characteristics, noise levels, weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Supply cable fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Low harmonic filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
400 V / 50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
460 V / 60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
AC input (supply) connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
DC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
JCU Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Compliance with the Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
C-Tick marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
UL marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

12 Table of contents
Patent protection in the US . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
11. Mains chokes
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
When is a mains choke required? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Installation guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
12. EMC filters
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
When is an EMC filter required? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
JFI-A1/JFI-B1 (Frame A/B, category C3) installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Installation guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Mounting procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
JFI-0x (Frames A…D, category C2) installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Installation guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
13. du/dt and common mode filtering
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
When is du/dt or common mode filtering required? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Filter types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
du/dt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Common mode filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
du/dt filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Common mode filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
14. Dimension drawings
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Frame size A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Frame size B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Frame size C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Frame size D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Mains chokes (type CHK-0x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
EMC filters (type JFI-x1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
JFI-A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
JFI-B1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
EMC filters (type JFI-0x) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Further information
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Table of contents 13
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

14 Table of contents

About this manual 15
About this manual
What this chapter contains
This chapter describes the intended audience and contents of this 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.
Compatibility
The manual is compatible with ACQ810-04 drive modules of frame sizes A to D.
Intended audience
This manual is intended for people who plan the 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 components and
electrical schematic symbols.
This manual is written for readers worldwide. Both SI and imperial units are shown
wherever appropriate.
Categorization according to the frame size
Some instructions, technical data and dimensional drawings which concern only
certain frame sizes are marked with the symbol of the frame size A, B, C or D. The
frame size is marked on the drive designation label. The frame size of each drive type
is also indicated in the rating tables in chapter Technical data.

16 About this manual
Categorization according to the + code
The instructions, technical data and dimensional drawings which concern only certain
optional selections are marked with + codes, e.g. +L500. The options included in the
drive can be identified from the + codes visible on the type designation label of the
drive. The + code selections are listed in chapter Operation principle and hardware
description under Type designation.
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.
About this manual lists the steps in checking the delivery and installing and
commissioning the drive and refers to chapters/sections in this manual and other
manuals for particular tasks.
Operation principle and hardware description describes the drive module.
Planning the cabinet assembly guides in planning the installation of the drive module
into a user-defined cabinet.
Mechanical installation instructs how to place and mount the drive.
Planning the electrical installation instructs on the motor and cable selection, the
protections and the cable routing.
Electrical installation instructs on how to wire the drive.
Installation checklist contains a list for checking the mechanical and electrical
installation of the drive.
Maintenance lists periodic maintenance actions along with work 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.
Mains chokes details the optional mains chokes available for the drive.
EMC filters details the EMC filtering options for the drive.
du/dt and common mode filtering lists the du/dt and common mode filtering options
available for the drive.
Dimension drawings contains the dimensional drawings of the drive and connected
equipment.

About this manual 17
Installation and commissioning flowchart
Task See
Identify the frame size of your drive: A, B, C or D. Drive designation label or Technical data:
Ratings (page 77)
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 assembly (page 27)
Planning the electrical installation (page
37)
Technical data (page 77)
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.
Mechanical installation: Contents of the
package (page 33)
If the converter has been non-operational
for more than one year, the converter DC
link capacitors need to be reformed. Ask
ABB for more information.
Check the installation site. Mechanical installation: Before installation
(page 35)
Technical data (page 77)
Install the drive in a cabinet. Mechanical installation: Installation
procedure (page 36)
Route the cables. Planning the electrical installation: Routing
the cables (page 46)
Check the insulation of the supply cable, the
motor and the motor cable.
Electrical installation: Checking the
insulation of the assembly (page 51)

18 About this manual
If the drive is about to be connected to an IT
(ungrounded) system, disconnect the internal
varistors and EMC filters. Also note that using an
EMC filter is not allowed in an IT (ungrounded)
system.
Safety instructions: Installation and
maintenance work (page 6)
Electrical installation: Power cable
connection (page 52)
Connect the power cables.
Connect the control and the auxiliary control
cables.
Electrical installation: Power cable
connection: (page 52) and Connecting the
control cables: (page 62)
For optional equipment:
Mains chokes (page 95)
EMC filters (page 99)
du/dt and common mode filtering (page
105)
Manuals for any optional equipment
Check the installation. Installation checklist (page 69)
Commission the drive. Appropriate Firmware manual
Operating of the drive: start, stop, speed control
etc.
Appropriate Firmware manual
Task See

About this manual 19
Terms and abbreviations
Term/Abbreviation Explanation
CHK-xx Series of optional mains chokes for the ACQ810.
EMC Electromagnetic Compatibility.
FIO-11 Optional analog I/O extension for the ACQ810.
FIO-21 Optional analog/digital I/O extension for the ACQ810.
FIO-31 Optional digital I/O extension for the ACQ810.
FDNA-0x Optional DeviceNet adapter for the ACQ810.
FENA-0x Optional Ethernet/IP adapter for the ACQ810.
FLON-0x Optional LONWORKS®adapter for the ACQ810.
FPBA-0x Optional PROFIBUS DP adapter for the ACQ810.
Frame (size) Size of the drive module. This manual deals with ACQ810-04
frames A, B, C and D. To determine the frame size of a drive
module, refer to the drive designation label attached to the drive,
or the rating tables in chapter Technical data.
FSCA-0x Optional Modbus adapter for the ACQ810.
IGBT Insulated Gate Bipolar Transistor; a voltage-controlled
semiconductor type widely used in inverters due to their easy
controllability and high switching frequency.
I/O Input/Output.
JCU The control unit of the drive module. The JCU is installed on top of
the power unit. The external I/O control signals are connected to
the JCU, or optional I/O extensions mounted on it.
JFI-xx Series of optional EMC filters for the ACQ810.
JMU The memory unit attached to the control unit of the drive.
RFI Radio-frequency interference.

20 About this manual