ABB ACS850-04 series User manual

ABB machinery drives
Hardware manual
ACS850-04 drive modules (0.37 to 45 kW, 0.5 to 60 hp)

List of related manuals
You can find manuals and other product documents in PDF format on the Internet. See section
Document library on the Internet on the inside of the back cover. For manuals not available in the
Document library, contact your local ABB representative.
Drive hardware manuals and guides Code (English)
ACS850-04 drive modules (0.37 to 45 kW, 0.5 to 60 hp) hardware manual 3AUA0000045496
ACS850-04 drive modules (0.37 to 45 kW, 0.5 to 60 hp) quick installation guide 3AUA0000045495
Safe torque off function for ACSM1, ACS850 and ACQ810 drives application
guide 3AFE68929814
Drive firmware manuals and guides
ACS850 standard control program firmware manual 3AUA0000045497
ACS850 standard control program quick start-up guide 3AUA0000045498
ACS850 crane control program supplement (to std ctrl prg) 3AUA0000081708
ACS850-04 drives with SynRM motors (option +N7502) supplement 3AUA0000123521
Option manuals and guides
Common DC configuration for ACS850-04 drives application guide 3AUA0000073108
ATEX-certified Safe disconnection function for ACS850 drives (+Q971)
application guide 3AUA0000074343
Application programming for ACS850 and ACQ810 drives application guide 3AUA0000078664
Manuals and quick guides for I/O extension modules, fieldbus adapters, etc.
ACS850-04 manuals

ACS850-04 drive modules
0.37 to 45 kW, 0.5 to 60 hp
Hardware manual
3AUA0000045496 Rev F
EN
EFFECTIVE: 2013-02-28
2013 ABB Oy. All Rights Reserved.

Safety instructions
5
Safety instructions
What this chapter contains
This chapter contains 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:
Electricity 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.

Safety instructions
6
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.
•Drives controlling a permanent magnet motor: A rotating permanent magnet
motor feeds power to the drive causing the drive to become live even when it is
stopped and the supply power switched off. Before maintenance work on the
drive,
– disconnect the motor from the drive by using a safety switch
– prevent the start-up of any other motors in the same mechanical system
– lock the motor shaft
– measure that the motor is in fact de-energised, then connect the U2, V2 and
W2 terminals of the drive to each other and to the PE.
•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 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 EMC filters 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.

Safety instructions
7
•The drive supports the Safe torque off function. See page 46.
•Standard EN 61800-5-1 (section 4.3.5.5.2.) requires that as the normal touch
current of the drive is higher than 3.5 mA AC or 10 mA DC, you must use a
fixed protective earth connection. In addition,
– install a second protective earthing conductor of the same cross-sectional
area as the original protective earthing conductor, or
– install a protective earthing conductor with a cross-section of at least 10 mm2
Cu or 16 mm2Al, or
– install a device which automatically disconnects the supply if the protective
earthing conductor breaks.
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 for
replacement.
•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.
•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.

Safety instructions
8
Start-up and operation
These warnings are intended for all who plan the operation of the drive, start up or
operate the drive.
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.
•Drives controlling a permanent magnet motor: Do not run the motor over the
rated speed. Motor overspeed leads to overvoltage which may permanently
damage the drive.
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
and brake resistor, if present) become hot when the system is in use.

Table of contents
9
Table of contents
List of related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety instructions
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Start-up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Table of contents
Introduction to this manual
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Categorization according to the frame size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Categorization according to the + code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Installation and commissioning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Operation principle and hardware description
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Main circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Power connections and control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Type designation key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Planning the cabinet assembly
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Cabinet construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Disposition of the devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Grounding of mounting structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Main dimensions and free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Cooling and degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Preventing the recirculation of hot air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Outside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Table of contents
10
Cabinets with multiple modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Cabinet heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Mechanical installation
Contents of the package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Delivery check and drive module identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Requirements for the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Direct surface mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
DIN rail mounting (Frames A and B only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Mains choke installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
EMC filter installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Brake resistor installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Planning the electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Motor selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Supply disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Other regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Thermal overload and short circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Thermal overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Protection against short-circuit in the motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Protection against short-circuit in the supply cable or the drive . . . . . . . . . . . . . . . . . . . . . . .44
Operating time of the fuses and circuit breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Circuit breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Motor thermal protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Ground fault protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Emergency stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Safe torque off function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Not allowed power cable type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Protecting the relay output contacts and attenuating disturbances in case of inductive loads . . . . .48
Considering the PELV requirements at sites above 2000 m (6562 ft) . . . . . . . . . . . . . . . . . . . . . . .49
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Connection of a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51