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ACS 600
This manual includes ? Safety ? Installation ? Maintenance ? Technical Data

Hardware Manual ACS/ACC/ACP 604/607/627 Frequency Converters 55 to 630 kW (75 to 700 HP)

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ACS 600 SingleDrive Manuals (English Originals)
GENERAL MANUALS (appropriate hardware manual is included in the delivery) ACS/ACC/ACP 601 Hardware Manual EN 61201360 2.2 to 110 kW ? Safety instructions ? Cable selection ? Mechanical and electrical installation ? Maintenance ? Technical data ? Dimensional drawings ACS/ACC 611 Supplement EN 61504443 (included in ACx 611 deliveries only) ? Safety instructions ? Installation ? Maintenance ? Fault tracing ? Parameters ? Technical data ? Dimensional drawings ACS/ACC/ACP 604/607/627 Hardware Manual EN 61201394, 55 to 630 kW ? Safety instructions ? Cable selection ? Mechanical and electrical installation ? Maintenance ? Technical data ACS/ACC/ACP 607/627 Dimensional Drawings 64484311, 55 to 630 kW ? Dimensional drawings ? Cable routing ACS/ACC 607/617/627/677 Hardware Manual EN 61329005 75 to 3000 kW ? Safety instructions ? Cable selection ? Mechanical and electrical installation ? Drive section commissioning ? Maintenance ? Technical data ACS/ACC 607/617/627/677 Dimensional Drawings EN 64488422, 75 to 3000 kW ? Dimensional drawings Converter Module Installation in User-defined Cabinet EN 61264922 (included in modules deliveries only) ? Safety instructions ? Cabinet design ? Wiring ? Installation checks ? Dimensional drawings ACS/ACC 624 Drive Modules Supplement EN 64186477 (included in ACx 624 module deliveries only) ? Safety instructions ? Technical data ? Dimensional drawings Thyristor Supply Sections User’s Manual (TSU) EN 64170597 ? TSU operation basics ? TSU firmware description ? TSU program parameters ? TSU commissioning

FIRMWARE MANUALS FOR DRIVE APPLICATION PROGRAMS (appropriate manual is included in the delivery) Standard EN 61201441 ? Control Panel use ? Standard application macros with external control connection diagrams ? Parameters of the Standard Application Program ? Fault tracing ? Fieldbus control Note: a separate Start-up Guide is attached Motion Control EN 61320130 ? Control Panel use ? Start-up ? Operation ? Parameters ? Fault tracing ? Fieldbus control Crane Drive EN 3BSE 011179 ? Commissioning of the Crane Drive Application Program ? Control Panel use ? Crane program description ? Parameters of the Crane Drive Application Program ? Fault tracing Pump and Fan Control (PFC) EN 61279008 ? Control Panel use ? Application macros ? Parameters ? Fault tracing ? Fieldbus control ? PFC application example System EN 63700177 ? Commissioning of the System Application Program ? Control Panel use ? Software description ? Parameters of the System Application Program ? Fault tracing ? Terms Application Program Template EN 63700185 ? Commissioning of the Drive Section ? Control Panel use ? Software description ? Parameters ? Fault tracing ? Terms

OPTION MANUALS (delivered with optional equipment) Fieldbus Adapters, I/O Extension Modules, Braking Choppers etc. ? Installation ? Programming ? Fault tracing ? Technical data

SUPPLY SECTION MANUALS (with 630 to 3000 kW units depending on the supply type one of these manuals is included in the delivery) Diode Supply Sections User’s Manual (DSU) EN 61451544 ? DSU specific safety instructions ? DSU hardware and software descriptions ? DSU commissioning ? Earth fault protection options

ACS/ACC/ACP 604/607/627 Frequency Converters 55 to 630 kW (75 to 700 HP) Hardware Manual

This manual concerns the ACS 607, ACS 627, ACC 607, ACC 627, ACP 607 and ACP 627 frequency converters and the ACS 604, ACC 604 and ACP 604 frequency converter modules. In the text, they are collectively referred to as ACx 604/6x7 or ACx 600.

3AFY 61201394 R0525 REV D EN EFFECTIVE: 15.6.2001 SUPERSEDES: 9.1.2001

? 2001 ABB Industry Oy. All Rights Reserved.

Safety Instructions

Overview

This chapter states the safety instructions that must be followed when installing, operating and servicing the ACS/ACC/ACP 604/607/627. If neglected, physical injury and death may follow, or damage may occur to the frequency converter, the motor and driven equipment. The material in this chapter must be studied before attempting any work on, or with, the unit. The following notation is used throughout the manual: Dangerous Voltage WARNING! warns of situations in which a high voltage can cause physical injury and/or damage equipment. The text next to this symbol describes ways to avoid the danger. General WARNING! warns of situations which can cause physical injury and/or damage equipment by means other than electrical. The text next to this symbol describes ways to avoid the danger. Electrostatic Discharge WARNING! warns of situations in which an electrostatic discharge can damage equipment. The text next to this symbol describes ways to avoid the danger. CAUTION! Note: Aims to draw special attention to a particular issue. Gives additional information or points out more information available on the subject.

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Installation and Maintenance Safety

These safety instructions are intended for all work on the ACx 604/607/ 627. Neglecting these instructions can cause physical injury and death. WARNING! All electrical installation and maintenance work on the ACx 600 should be carried out by qualified electricians. Do not attempt any work on a powered ACx 600. After switching off the mains, always allow the intermediate circuit capacitors 5 minutes to discharge before working on the frequency converter, the motor or the motor cable. The voltage between each input terminal (U1, V1, W1) and earth must be measured with a multimeter (impedance at least 1 MW) to ensure that the frequency converter is discharged before beginning work. All insulation tests must be carried out with the ACx 600 disconnected from the cabling. The ACx 600 motor cable terminals are at a dangerously high voltage when input power is applied, regardless of motor operation. No work on the motor cable should be attempted with mains power applied. The brake control terminals (UDC+, UDC-, R+ and R- terminals) carry a dangerous DC voltage (over 500 V). There can be dangerous voltages inside the ACx 600 from external control circuits when the ACx 600 input power is shut off. No work on the control cables should be attempted when power is applied to the frequency converter or to the external control circuits. Exercise appropriate care when working with the unit.

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Safety Instructions

Permanent Magnet Motor

WARNING! Installation and maintenance work When a permanent magnet motor is connected to the drive, ensure that the driven machine cannot rotate the motor during installation and maintenance work. When rotating, the permanent magnet motor feeds power to the intermediate circuit of the drive and also the supply connections become live (even when the inverter is stopped!). Disconnect the motor from the drive with a safety switch, or lock the motor shaft and earth the motor connection terminals temporarily by connecting them together as well as to the PE. Normal use Ensure that the permanent magnet motor cannot rotate at too high a speed. Overspeed leads to overvoltage which may explode the capacitors in the intermediate circuit of the drive. Permanent magnet motor may be used with ACS 600 Permanent Magnet Synchronous Motor (PMSM) System Application Program, or with other application programs in scalar control mode only.

Supply Connections

ACx 6x7 units include an on-load isolating switch fuse with handle in the front door. This switch fuse does not switch off the power from the EMC Line Filter of ACS/ACC 6x7-0400-3, -0490-3/5/6, -0610-3/5/6 and -0760-5/6 units. For ACS/ACC 6x7-0400-3, -0490-3/5/6, -0610-3/5/6 and -0760-5/6 units with EMC Line Filter and for the ACx 604 module, a supply disconnecting device must be installed in the supply, by which the electric parts of the unit can be separated from the mains (power) network during installation and maintenance work. The supply disconnecting device must be locked to the open position during installation and maintenance work.

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To meet the European Union Directives, the disconnecting device shall fulfil the requirements of EN 60204-1 chapter 5.3.3. and shall be one of the following types: ? a switch-disconnector, in accordance with IEC 60947-3, utilization category AC-23B or DC-23B ? a disconnector in accordance with IEC 60947-3, that has an auxiliary contact that in all cases causes switching devices to break the load circuit before the opening of the main contacts of the disconnector. It is not allowed to install an ACx 604/6x7 with the EMC Filter options (code 0 or 3 in the type code for EMC Filters) to unearthed mains (an ungrounded power system or a high resistance grounded power system (over 30 ohms)). The mains will be connected to earth potential through the EMC filter of the ACx 600 which may cause danger or damage the unit. Disconnect the EMC filter capacitors before connecting the ACx 600 to unearthed mains. For detailed instructions on how to do this, please contact your local ABB distributor. The motor must not be controlled with the supply disconnecting device; instead, the and keys of the Control Panel or commands via the digital inputs (NIOC board) or serial communication (NAMC board) of the ACx 600 should be used. The maximum number of charging cycles of the d.c. capacitors of ACx 600 (i.e. power-ups by applying the input power) is five in ten minutes. WARNING! Never connect the mains (line power) to the ACx 600 output. If frequent bypassing is required, employ mechanically connected switches or contactors that prevent simultaneous connection of the motor to the supply network and to the output of the ACx 600. Mains (line) voltage applied to the output can result in permanent damage to the unit. Operation outside the nominal voltage range should not be attempted, as overvoltages can result in permanent damage to the ACx 600.

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Safety Instructions

Earth (Ground) Fault Protective Function

The ACx 600 is equipped with an internal earth fault protective function to protect the unit against earth faults in the inverter, the motor and the motor cable. This is not a personal safety or a fire protection feature. The earth fault protective function can be disabled by Parameter 30.17 EARTH FAULT (Standard Application Program) and Parameter 30.11 (Crane Application Program). The internal earth fault protective function is not in use in the 12-pulse supplied units. For ACS 62x units, refer to subsection Special for ACx 6x7 Units from 315 to 630 kW. The EMC filter of the ACx 600 includes capacitors connected between the main circuit and the frame. These capacitors increase the earth (ground) leakage current through the PE connector to the mains (line) which may cause some fault current circuit breakers to function.

Power Loss Ridethrough Function

WARNING! When equipped with a main contactor option, the drive also includes a Power Loss Ride-through function which keeps the drive control live during during a short main supply break. If this function is not safe for your prosess, inactivate it according to the instructions given in ACS/ACC/ACP 607 Contactor Option Information on the Power Loss Ride-through Function (EN code 64354949).

Emergency Stop Devices

Emergency stop devices must be installed at each operator control station and at other operating stations where emergency stop may be required. Pressing the key on the Control Panel of ACx 600 does not generate an emergency stop of the motor or separate the drive from dangerous potential. Line Contactor and Emergency Stop Switch are factory installed as option for ACx 6x7.

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Safety Instructions

Motor Connections
WARNING! Operation is not allowed if the motor nominal voltage is less than 1/2 of (ACP: 0.4 times) the ACx 600 nominal input voltage, or the motor nominal current is less than 1/6 of the ACx 600 nominal output current I2hd. Pulses in the Drive Output As with all frequency converters employing the most modern IGBT inverter technology, the ACx 600 output comprises – regardless of output frequency – pulses of approximately 1.35 times the mains network voltage with a very short rise time. The voltage of the pulses can be almost double at the motor terminals, depending on the motor cable properties. This in turn can cause additional stress on the motor insulation. Modern variable speed drives with their fast rising voltage pulses and high switching frequencies can cause current pulses through the motor bearings which can gradually erode the bearing races. Protecting the Motor Winding Protecting the Motor Bearings The stress on motor insulation can be avoided by using optional ABB du/dt filters. du/dt filters also reduce bearing currents. To avoid damage to motor bearings, insulated N-end (non-driven end) bearings and output filters from ABB must be used according to the following table. In addition, the cables must be selected and installed according to the instructions given in this manual. Three types of filters are used individually or in combinations: 1. 2. 3. optional ACS 600 du/dt filter (protects motor insulation system and reduces bearing currents) ACS 600 common mode filter (mainly reduces bearing currents) ACS 600 light common mode filter (mainly reduces bearing currents).

The common mode filter is composed of toroidal cores installed onto the motor cable. Requirements Table The following table shows how to select the motor insulation system and when optional ACS 600 du/dt filters, insulated N-end (non-driven end) motor bearings and ACS 600 common mode filters are required. The motor manufacturer should be consulted regarding the construction of the motor insulation and additional requirements for explosion-safe motors. Failure of the motor to fulfil the following requirements or improper installation may shorten motor life or damage the motor bearings.

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Manufacturer

Requirement for Motor Type Nominal Mains Voltage Motor Insulation System ACS 600 du/dt Filter, Insulated N-end bearing and ACS 600 Common Mode Filter PN < 100 kW and Frame Size < IEC 315 + du/dt 100 kW < PN < 350 kW or Frame Size > IEC 315 +N + du/dt PN > 350 kW

A B B

Randomwound M2_ and M3_

UN < 500 V 500 V < UN < 600 V

Standard Standard or Reinforced

+ N + CMF + du/dt + N + LCMF

+ du/dt n.a.

+N + du/dt + N + CMF

+ N + CMF + du/dt + N + LCMF + N + CMF

600 V < UN < 690 V Form-wound 380 V < UN < 690 V HXR and AM_ Old* formwound HX_ and modular Randomwound HXR N O N A B B Randomwound and form-wound 380 V < UN < 690 V

Reinforced Standard

Check with the + du/dt filter with voltages over 500 V + N + CMF motor manufacturer. Check with the + du/dt filter with voltages over 500 V + N + CMF motor manufacturer. Standard: ?LL = 1300 V Standard: ?LL = 1300 V + du/dt + N or CMF + du/dt + N or + du/dt + CMF or Reinforced: ?LL = 1600 V, 0.2 microsecond rise time + N or CMF + N + CMF + N + CMF + du/dt + N + CMF

380 V < UN < 690 V

UN < 420 V 420 V < UN < 500 V

500 V < UN < 600 V

Reinforced: ?LL = 1600 V or Reinforced: ?LL = 1800 V

+ du/dt

+ du/dt

+ du/dt + N + LCMF

+ du/dt n.a.

+ N or CMF + du/dt + N + CMF

+ N + CMF + du/dt + N + LCMF + N + CMF

600 V < UN < 690 V Form-wound 600 V < UN < 690 V

Reinforced: ?LL = 1800 V Reinforced: ?LL = 2000 V, 0.3 microsecond rise time

* manufactured before 1992

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Safety Instructions

Note 1: The abbreviations used in the table are defined below.
Abbreviation Definition UN nominal mains voltage peak line-to-line voltage at motor terminals which the motor insulation must withstand motor nominal power du/dt filter common mode filter: 3 toroidal cores per each motor cable light common mode filter: 1 toroidal core per each motor cable N-end bearing: insulated motor non-driven end bearing Motors of this power range are not available as standard units. Consult the motor manufacturer.

?LL
PN du/dt CMF LCMF N n.a.

Note 2: ACA 635 IGBT Supply Sections and the ACS/ACC 611 If voltage is raised by the ACA 635 or the ACS/ACC 611, select the motor insulation system according to the increased intermediate circuit d.c. voltage level, especially in the 500 V (+10%) supply voltage range. Note 3: HXR and AMA Motors All AMA machines (manufactured in Helsinki) to be supplied by a frequency converter have form-wound windings. All HXR machines manufactured in Helsinki since 1997 have form-wound windings. Note 4: Chopper Resistor Braking When the drive is in braking mode for a large part of its operation time, the intermediate circuit DC voltage of the drive increases, the effect being similar to increasing the supply voltage by up to 20 percent. This should be taken into consideration when determining the motor insulation requirement. Example: Motor insulation requirement for a 400 V application must be selected as if the drive were supplied with 480 V. Note 5: This table applies to NEMA motors with the following heading.
PN < 134 HP and Frame Size < NEMA 500 134 HP < PN < 469 HP or Frame Size > NEMA 500 PN > 469 HP

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Safety Instructions
Note 6: Calculating the Rise Time and the Peak Line-to-line Voltage The peak line-to-line voltage at the motor terminals generated by the ACS 600 as well as the voltage rise time depend on the cable length. The requirements for the motor insulation system given in the table are “worst case” requirements covering the ACS 600 installations with 30 metre and longer cables. The rise time can be calculated as follows: t = 0.8 · ?LL/(du/dt). Read ?LL and du/dt from the diagrams below.

4 3.5 3 2.5 2 1.5 1 0.5 0 0 100 200 300 400 Cable length (m) ?LL/ UN

4 3.5 3 2.5 2 1.5 1 0.5 0 0 100 200 300 400 Cable length (m) ?LL/ UN

du/dt / (kV/ms)

du/dt / (kV/ms)

Without du/dt Filter

With du/dt Filter

WARNING! The ACx 600 introduces electric motors, drive train mechanisms and driven machines to an extended operating range. It should be determined from the outset that all equipment is up to these conditions.

WARNING! There are several automatic reset functions in the ACS 600 (with Standard Application Program). If selected, they reset the unit and resume operation after a fault. These functions should not be selected if other equipment is not compatible with this kind of operation, or dangerous situations can be caused by such action.

WARNING! If an external source for start command is selected and it is ON, the ACS 600 (with Standard Application Program) will start immediately after fault reset.

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Safety Instructions

Power Factor Compensation Capacitors

Power factor compensation capacitors and surge absorbers must not be connected to the motor cables. These devices are not designed to be used with frequency converters, and will degrade motor control accuracy. They can cause permanent damage to the ACx 600 or themselves due to the rapid changes in the ACx 600 output voltage. If there are power factor compensation capacitors in parallel with the ACx 600 make sure that the capacitors and the ACx 600 are not charged simultaneously to avoid voltage surges which might damage the unit.

Output Contactors

If a contactor is used between the output of the ACx 600 and the motor with DTC control mode selected, the output voltage of the ACx 600 must be controlled to zero before the contactor is opened. Otherwise the contactor will be damaged. With Standard Application Program, check the settings of Parameters 21.03 STOP FUNCTION and 16.01 RUN ENABLE. For program version 6.x, check also Parameter 21.07 RUN ENABLE FUNC. (For further information, see the Firmware Manual.) In scalar control the contactor can be opened with ACS/ACC 600 running. Varistors or RC networks (AC) or diodes (DC) should be used to protect against voltage transients generated by contactor coils. The protective components should be mounted as close as possible to the contactor coils. Protective components should not be installed at the NIOC board terminal block.

Relay Contacts

When used with inductive loads (relays, contactors, motors), the relay contacts of ACx 600 must be protected with varistors or RC networks (AC) or diodes (DC) against voltage transients. The protective components should not be installed at the NIOC board terminal block. The ACx 600 and adjoining equipment must be properly earthed. The ACx 600 and the motor must be earthed at the installation site to ensure personnel safety in all circumstances and in addition to reduce electromagnetic emission and pick-up. Make sure that earthing (grounding) conductors are adequately sized as required by safety regulations.

Earth (Ground) Connections

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In CE compliant installations and in other installations where EMC emissions must be minimized, 360° high frequency earthing (grounding) of cable entries is done in order to suppress electromagnetic disturbances. In addition, cable screens have to be connected to protective earth (PE) in order to meet safety regulations. Power cable screens are suitable for use as equipment earthing (grounding) conductors only when the screen conductors are adequately sized as required by safety regulations. The ACx 600 earth (ground) terminals should not be connected in series in case of a multiple installation. Incorrect earthing can cause physical injury, death or equipment malfunction and increase electromagnetic interference.

Components Connected to Digital/ Analogue Inputs

WARNING! IEC 664 requires double or reinforced insulation between live parts and the surface of accessible parts of electrical equipment which are either non-conductive or conductive but not connected to the protective earth. To fulfil this requirement, the connection of a thermistor (and other similar components) to the digital inputs of ACx 600 can be implemented in three alternate ways: 1. There is double or reinforced insulation between the thermistor and live parts of the motor. 2. Circuits connected to all digital and analogue inputs of the ACx 600 are protected against contact, and insulated with basic insulation (the same voltage level as the converter main circuit) from other low voltage circuits. 3. An external thermistor relay is used. The insulation of the relay must be rated for the same voltage level as the converter main circuit.

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EMC
Note: If safety switches, contactors, connection boxes or similar equipment are used in the motor cable, they should be installed in a metal enclosure with 360 degrees earthing for the screens of both the incoming cable and the outgoing cable, or the screens of the cables should otherwise be connected together.

WARNING! The printed circuit boards contain integrated circuits that are extremely sensitive to electrostatic discharge. Exercise appropriate care when working on the unit to avoid permanent damage to the circuits. Do not touch the boards unnecessarily.

Cooling
WARNING! The cooling air flows and space requirements must be fulfilled. Special attention must be paid to cooling if units are installed in confined spaces and user defined cabinets. Air flow from below, e.g. a cable conduit, into the cabinet must be prevented. This is essential for fire safety reasons, and to retain the original degree of protection. For best results, use the lead-through plates delivered with the unit.

Mechanical Installation

CAUTION! The ACx 6x7 should only be transported on the original pallet, or with a proper lifting device using the lifting lugs on top of the cabinet. The frequency converter is not intended to be lifted by running lines under the unit. The ACx 6x7 centre of gravity is quite high, and there is the risk of overturning. The ACx 6x7 can be laid on its back to fit through confined spaces. Exercise appropriate care when manoeuvring the unit to avoid damage and injury. This work should only be attempted with two or more people working together. CAUTION! Make sure that dust from drilling does not enter the ACx 600 when installing. Electrically conductive dust inside the unit may cause damage or lead to malfunction. CAUTION! The ACx 6x7 should not be fastened by any other point than the holes at its base or the fastening hooks. Do not fasten the ACx 600 by riveting or welding.

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Special for ACx 6x7 Units from 315 to 630 kW

For types ACx 6x7-0400-3 and -0490-5/6 and up note the following issues.

WARNING! Make sure that the ACx 6x7 is disconnected from the mains network during installation. The switch fuse (with handle in the front door) of the ACx 6x7 does not switch off power from the EMC Line Filter. Disconnect the ACx 6x7 with EMC Line Filter from the mains network at the distribution board. Wait for 5 minutes before working on the frequency converter, the motor or the motor cable. Note: On units not equipped with main contactors, additional wiring by the commissioner is required for activation of the mains fuse supervision of the ACx 6x7 and the earth fault detection functions of the ACx 627. It is recommended that these functions be wired to switch off the mains supply should a fuse failure or an earth fault occur. Refer to the circuit diagrams (Sheet 50) supplied with the unit and Chapter 3 – Electrical Installation (Types ACx 6x7-0400-3, -0490-5/6 and up), or contact your ABB representative for information.

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ACS/ACC/ACP 604/6x7 Frequency Converters

Table of Contents

ACS 600 SingleDrive Manuals (English Originals) Safety Instructions Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii CAUTION! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Note: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Installation and Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv Permanent Magnet Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v Supply Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v Earth (Ground) Fault Protective Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii Power Loss Ride-through Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii Emergency Stop Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii Motor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .viii Pulses in the Drive Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii Protecting the Motor Winding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii Protecting the Motor Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii Requirements Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii Power Factor Compensation Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii Output Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii Relay Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii Earth (Ground) Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii Components Connected to Digital/Analogue Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xiii EMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv Special for ACx 6x7 Units from 315 to 630 kW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv Note: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv Table of Contents Chapter 1 – Introduction General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Other Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Delivery Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 ACx 6x4/6x7 Type Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Chapter 2 – Mechanical Installation Fastening the Cabinet to the Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Fastening Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 Holes inside the Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

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Chapter 3 – Electrical Installation Insulation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Mains Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Input Cable Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Cabling Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Alternative Power Cable Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Motor Cable Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Special for Types ACx 6x7-0400-3, -0490-5 and -0490-6 and up . . . . . . . . . . . . . . . . . . . . . . . 3-4 Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 Cable Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Mains, Motor and Control Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Frame Sizes R7 to R9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Types ACx 6x7-0400-3, -0490-5/6 and up (2 x R8 and 2 x R9) . . . . . . . . . . . . . . . . . . . . . . . 3-13 Control Cable Connecting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 Pulse Encoder Insulation (ACP 600) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Pulse Encoder Phasing (ACP 600, NIOCP Board) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Installation of Optional Modules and DriveWindow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Installation of Other Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23 Chapter 4 – Installation Checklist Installation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Chapter 5 – Maintenance Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Control Panel Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5 Appendix A – ACS/ACC/ACP 604/6x7 Technical Data IEC Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 NEMA Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 Output Current Temperature Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 Input Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Motor Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Efficiency and Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7 Cable Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7 Terms used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7 Terminal Sizes and Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8

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External Control Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9 NIOC Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10 Optional Terminal Block X2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11 Optional Terminal Block 2TB (US Version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12 NIOCP Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13 NIOC Board Chaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-14 NIOC and NIOCP Board Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-15 Encoder Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-18 Enclosures, Space Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-19 Cooling Air Flow Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-20 Heat Losses and Noise Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-20 Dimensions and Weights (ACx 604) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-21 Dimensions and Weights (ACx 6x7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-22 Braking Chopper Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-23 Application Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-24 Application Macros . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-24 Macro/Language Combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-25 Protection Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-26 Applicable Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-27 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-27 Transportation Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-27 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-28 CE Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-28 Compliance with the EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-28 Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-30 UL/CSA Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-30 UL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-30 “C-tick” Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-30 Compliance with AS/NZS 2064 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-30 Equipment Warranty and Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-31 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-32

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Chapter 1 – Introduction

General

The ACS 600 product family of three phase frequency converters and converter modules for speed control of squirrel cage electric motors includes ? the ACS 600 (for most applications) ? the ACP 600 (for positioning, synchronising and other highprecision control applications) ? the ACC 600 (for crane drive applications) ? the ACS 600 MultiDrive (for multidrive applications) The application programs are introduced in Appendix – A. Study this manual carefully before storaging, installing, commissioning, operating or servicing the frequency converter. We expect that you have a basic knowledge of physical and electrical fundamentals, electrical wiring practices, electrical components and electrical schematic symbols. Other Manuals Items concerning the ACx 6x4/6x7 in other manuals are listed below. For EN codes of the manuals refer to inside of the front cover of this manual.
See ACS/ACC/ACP 607/627 Dimensional Drawings Start-up Guide for ACS 600 Standard Application Program. If the ACx 600 is equipped with another application program, see the appropriate Firmware Manual. Converter Module Installation in User-defined Cabinet ACS/ACC 624 Drive Modules Supplement their manuals the appropriate Firmware Manual

For dimensional drawings, cable routing inside the cabinet start-up ACx 604 modules and 624 modules from 315 to 700 kW ACx 624 modules from 75 to 315 kW optional equipment programming the unit

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Chapter 1 – Introduction

Delivery Check

Check that there are no signs of damage. Before attempting installation and operation, check the information on the frequency converter nameplate to verify that the unit is of the correct model. Each ACx 600 is fitted with a nameplate for identification purposes. The nameplate data includes a type code and a serial number, which allow individual recognition of each unit. The type code contains information on the properties and configuration of the unit. The first digit of the serial number refers to the manufacturing plant. The next four digits refer to the unit’s manufacturing year and week, respectively. The remaining digits complete the serial number so that there are no two units with the same serial number.

ACx 6x4/6x7 Type Code

The meaning of the main selections of the ACx 6x4/6x7 type code characters is given in the table below. Not all selections are available for all types. More information on selections is given in ACS 600 SingleDrive Ordering Information guide (code: 58977985, available on request).
Character Meaning no. Example: ACS60701003000B1200901 1 Product Category A = AC Drive 2...3 Product Type CS = Standard, CC = Crane Drive, CP = MotionControl 4 Product Family 6 = ACS 600 5 Input Bridge 0 = 6-pulse rectifier, 2 = 12-pulse rectifier, 7 = Regenerative 4Q thyristor bridge 6 Construction 1 = Wall mounted, 4 = Module, 7 = Cabinet 7..10 Power Rating (kVA) 11 Voltage Rating 3 = 380/400/415 V a.c. 4 = 380/400/415/440/460/480/500 V a.c. 5 = 380/400/415/440/460/480/500 V a.c. 6 = 525/550/575/600/660/690 V a.c. Option 1, Option 2, Option 3 Application Software x = Languages and Application Macro Options Control Panel 0 = None, 1 = Control Panel included, 4 = Customer I/O Terminal Block X2, 5 = 1 + 4 Refer to

Appendix A: Ratings

12...14 15

Appendix A: Application Programs

16

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Chapter 1 – Introduction

Character Meaning no. 17 Degree of Protection 0 = IP 00 (chassis), A = IP 21, 2 = IP 22, 4 = IP 42, 5 = IP 54, 6 = IP 00 with Coated Boards, 7 = IP 22 with Coated Boards, 8 = IP 42 with Coated Boards 9 = IP 54 with Coated Boards B = IP 21 with Coated Boards 18 Line Input and Protection Options 19 Starter for Auxiliary Motor Fan 20 Filters 0 = with EMC Filters (not for 690V or 12-pulse rectifier) 3 = with output du/dt Filters + EMC Filters (not for 690V) 5 = Output du/dt Filters + no EMC Filters 8 = No CE, no EMC filters, US conduit (ACS 607 only, 115 VAC transformer secondary; compliant with NFPA 90) 9 = without EMC Filters A = Common Mode Filter B = Common Mode Filter + EMC Filter (not for 690V) C = du/dt Filter + Light Common Mode filter D = du/dt Filter + Light Common Mode filter + EMC Filter (not for 690V) E = du/dt Filter + Common Mode Filter F = du/dt Filter + Common Mode Filter + EMC Filter (not for 690V) G = Light Common Mode Filter 21 ACx 607: Braking Chopper and Cabling Direction ACx 604: R = NDCU control unit outside the module 0 = NIOC and NAMC boards inside the module 22 Other Options

Refer to Appendix A: Enclosures

Appendix A: CE marking

Inquiries

Any inquiries about the product should be addressed to the local ABB representative, quoting the type code and the serial number of the unit. If the local ABB representative cannot be contacted, inquiries should be addressed to ABB Industry, Helsinki, Finland.

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Chapter 1 – Introduction

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ACS/ACC/ACP 604/6x7 Frequency Converters

Chapter 2 – Mechanical Installation

See Appendix A – ACS/ACC/ACP 604/6x7 Technical Data for allowed operation conditions of the ACx 604/6x7. For installation of ACx 604 module in a cabinet refer to a supplement to this manual: Converter Module Installation in User-defined Cabinet (EN code: 61264922). The ACx 6x7 should be installed in an upright vertical position. The floor that the unit is installed on should be of non-flammable material, as smooth as possible, and strong enough to support the weight of the unit. The maximum allowed deviation from the surface level must be < 2 mm measured every 1 m. The installation site should be levelled (when needed), as the ACx 6x7 is not equipped with adjustable feet. The ACx 6x7 can be installed on elevated floor and over a cable duct. The integrity of the supporting structure must be checked before the ACx 6x7 is placed in such a position. ACx 6x7 can be installed with its back against a wall. Sufficient room around the ACx 6x7 is required to enable cooling air flow, service and maintenance. The wall behind the unit should be of non-flammable material.

Fastening the Cabinet to the Floor

Fastening the cabinet to the floor is especially important in installations subjected to vibration or other movement. Fasten the cabinet to the floor with bolts through the holes at its base or from outside with fastening clamps attached to its bottom front (and back edges if not installed against wall). Check the intended installation site for sufficient room. Check that there is nothing on the floor to inhibit installation. See the dimensional drawings in ACS/ACC/ACP 607/627 Dimensional Drawings. Make cable duct opening if cables come from a cable duct. Smooth cable duct edges if required.

ACS/ACC/ACP 6x7 Frequency Converters

2-1

Chapter 2 – Mechanical Installation

Fastening Clamps

Insert the clamp into the longitudinal hole in the edge of the cabinet frame body and fasten it with a bolt to the floor. The longitudinal holes for fixing are marked in the dimensional drawings.

Cabinet frame body

Cabinet frame body

Dimensions of the fastening clamp

Holes inside the Cabinet

1. See ACS/ACC/ACP 607/627 Dimensional Drawings for the fastening hole locations. 2 Make holes for bolts to the floor. Insert plugs into the fastening holes. 3. Place the frequency converter carefully onto the holes. 4. Place bolts in the plugs. 5. Tighten the bolts.

2-2

ACS/ACC/ACP 6x7 Frequency Converters

Chapter 3 – Electrical Installation

WARNING! The electrical installation described in this chapter should only be carried out by a qualified electrician. The Safety Instructions on the first pages of this manual must be followed. Negligence of these instructions can cause injury or death.

Insulation Checks

Every ACx 600 unit has been tested for insulation between main circuit and chassis (2500 V rms 50 Hz for 1 second) at the factory. Therefore there is no need to check the insulation on the unit again. When checking the insulation of the assembly, proceed in the following manner: WARNING! Insulation checks must be performed before connecting the ACx 600 to the mains. Before proceeding with the insulation resistance measurements make sure that the ACx 600 is disconnected from the mains. 1. 2. Check that the motor cable is disconnected from the ACx 600 output terminals U2, V2 and W2. Measure the insulation resistances of motor cable and the motor between each phase and Protective Earth with measuring voltage 1 kV d.c. The insulation resistance must be higher than 1 MW.

W
PE

M

Mains Fuses

Fuses are needed to protect the input bridge of the ACx 600 in case of an internal short circuit. The ACx 6x7 is equipped with internal input fuses introduced in Appendix A – ACS/ACC/ACP 604/6x7 Technical Data. The ACx 604 is not equipped with input fuses. When installing the ACx 604, you must always connect the supply via ultrarapid fuses given in Appendix A – ACS/ACC/ACP 604/6x7 Technical Data. If a fuse is blown, it must not be replaced with a normal slow fuse rated according to Appendix A – ACS/ACC/ACP 604/6x7 Technical Data. An ultrarapid fuse must be used. The ACx 600 protects the input and motor cables from overload when the cables are dimensioned according to the nominal current of the ACx 600. When the ultrarapid fuses of the ACx 604 are placed at the distribution board, they protect the input cable in case of a short circuit.

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Chapter 3 – Electrical Installation

Input Cable Protection

Normal slow fuses can be used to protect the input cable in case of a short circuit. (They do not protect the input bridge of ACx 600 in case of a short circuit.) Slow fuses must be dimensioned according to local safety regulations, appropriate mains voltage and the rated current of the ACx 600 (see Appendix A – ACS/ACC/ACP 604/6x7 Technical Data).

Cabling Instructions Power Cables
The mains and motor cables must be dimensioned according to local regulations: 1. 2. The cable must be able to carry the ACx 600 load current. The cable terminals of ACx 600 warm up to 60 °C (140 °F) during operation. The cable must be rated for at least 60 °C (140 °F) maximum operating temperature. The cable must fulfil the requirements of the short-circuit protection used. The inductance and impedance of the cable must be rated according to permissible touch voltage appearing under fault conditions (so that the fault point voltage will not rise too high when an earth fault occurs).

3 4.

The voltage rating of the mains cables should be 1 kV for 690 VAC rated equipment. For the North American market, 600 VAC rated cable is accepted for 600 VAC rated equipment. Voltage rating for the motor cables should be minimum 1 kV as a general rule. Symmetrical shielded motor cable must be used (figure below). Four-conductor system is allowed for mains cabling, but shielded symmetrical cable is recommended. To operate as a protective conductor, the shield conductivity must be at least 50 % of the conductivity of the phase lead. Compared to a four-conductor system, the use of symmetrical shielded cable reduces electromagnetic emission of the whole drive system as well as motor bearing currents and wear. The motor cable and its PE pigtail (twisted screen) should be kept as short as possible in order to reduce electromagnetic emission as well as capacitive current.

3-2

ACS/ACC/ACP 604/6x7 Frequency Converters

Chapter 3 – Electrical Installation

Alternative Power Cable Types

Power cable types that can be used with the ACx 600 are represented below.

Recommended Symmetrical shielded cable: three phase conductors and a concentric or otherwise symmetrically constructed PE conductor, and a shield PE conductor and shield Shield A separate PE conductor is required if the conductivity of the cable shield is < 50 % of the conductivity of the phase conductor. Shield

PE

PE

A four-conductor system: three phase conductors and a protective conductor. Not allowed for motor cables.

PE

Shield

Motor Cable Shield

To effectively supress radiated and conducted radio-frequency emissions, the shield conductivity must be at least 1/10 of the phase conductor conductivity. One way of evaluating the effectiveness of the shield is the shield inductance, which must be low and only slightly dependent on the frequency. These requirements are easily met with a copper or aluminium shield/armour. The minimum requirement of the motor cable shield of the ACx 600 is shown below. It consists of a concentric layer of copper wires with an open helix of copper tape. The better and tighter the shield, the lower the emission level and the bearing currents.
Copper wire screen Helix of copper tape Inner insulation

Insulation jacket

Cable core

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Chapter 3 – Electrical Installation

Special for Types ACx 6x7-0400-3, -0490-5 and -0490-6 and up Motor Cable

For compliance with the European Union EMC Directive, the ACx 6x7 must be installed with screened power cables specified below. For information on other equivalent cables, please contact your local ABB distributor. The motor cable used in the ACx 6x7 frequency converter installation must be a symmetrical three conductor screened cable in order to fulfil the radiated emission requirements stated in the generic emission standard for industrial environment EN 61800-3. The cable types MCCMK and AMCCMK (from NK Cables, Finland) and VUSO and VO-YMvK-as from DRAKA KABEL have been tested and approved by ABB Industry. Equivalent cables from other manufacturers that fulfil the requirements can be used in the installation of ACx 6x7 as well. The suitability of a cable type can be decided on the grounds of either screen construction or transfer impedance. The general rule for the cable screen effectiveness is: the better and tighter the screen of the cable, the lower the radiated emission level. There are two kinds of cable screen constructions that fulfil the minimum requirement of screen effectiveness: a screen consisting of a layer of copper tape (overlapping each round) and a concentric layer of copper wires (figure a below), or a screen consisting of a braided galvanised steel wire (item b below).
Spiral wrapped copper wire screen Wrapped copper tape

Insulation jacket

Inner insulation

a)

Cable core

Tape overlap

Insulation jacket

Braided metallic screen

Inner insulation

b)

Cable core

3-4

ACS/ACC/ACP 604/6x7 Frequency Converters

Chapter 3 – Electrical Installation

Mains Cable

The mains cable used in the installation must be a three- or fourconductor screened cable. The cable types MCMK and AMCMK from NK Cables have been tested and approved by ABB Industry. The mains cable screen of an equivalent cable must at least consist of a concentric layer of copper wires with an open helix of copper tape connecting the wires together and reducing the size of the holes in the screen (figure on page 3-3). However, motor cables with better shielding (eg. braided screen) emit considerably less high frequency interference.

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Chapter 3 – Electrical Installation

Control Cables

All control cables must be shielded. As a general rule, the control signal cable shield should be earthed directly in the ACx 600. The other end of the shield should be left unconnected or earthed indirectly via some nanofarad high-frequency, high-voltage capacitor (e.g. 3.3 nF / 3000 V). The screen can also be earthed directly at both ends if they are in the same earth line with no significant voltage drop between the end points. Twisting the signal wire with its return wire reduces disturbances caused by inductive coupling. Pairs should be twisted as close to terminals as possible. A double shielded twisted pair cable (figure a, e.g. JAMAK by NK Cables, Finland) must be used for analogue signals and is recommended for the pulse encoder signals. Employ one individually shielded pair for each signal. Do not use common return for different analogue signals. A double shielded cable is the best alternative for low voltage digital signals but single shielded twisted multipair cable (figure b) is also usable.

a A double shielded twisted pair cable

b A single shielded twisted multipair cable

The analogue and digital signals should be run in separate, screened cables. Relay-controlled signals, providing their voltage does not exceed 48 V, can be run in the same cables as digital input signals. It is recommended that the relay-controlled signals be run as twisted pairs. Never mix 24 VDC and 115 / 230 VAC signals in the same cable. Relay Cable The cable type with braided metallic screen (e.g. ?LFLEX, LAPPKABEL, Germany) has been tested and approved by ABB Industry. Min. 4 · 0.25 mm2 + 2 · 0.5 mm2, min. single shielded twisted multipair cable, optical coverage > 91 %. The maximum cable length is 150 m. Suitable cable is available from ABB.

Encoder Cable (ACP 600)

3-6

ACS/ACC/ACP 604/6x7 Frequency Converters

Chapter 3 – Electrical Installation

Control Panel Cable

In remote use the cable connecting the Control Panel to the ACx 600 must not exceed 3 metres. The cable type tested and approved by ABB Industry is used in Control Panel option kits. The motor cable should be installed away from other cable routes. Motor cables of several frequency converters can be run in parallel installed next to each other. It is recommended that the motor cable, mains cable and control cables be installed on separate trays (minimum distance 500 mm). Long parallel runs of motor cable with other cables should be avoided in order to decrease electromagnetic interference caused by the rapid changes in the frequency converter output voltage. Where control cables must cross power cables make sure they are arranged at an angle as near to 90 degrees as possible. Extra cables should not be run through the ACx 600. The cable trays shall have good electrical bonding to each other and to the earthing eletrodes. Aluminium tray systems can be used to improve local equalizing of potential. Below is a diagram of cable routing. ACx 6x7 Mains cable 90 ° Control cables Motor cable min 500 mm

Cable Routing

ACS/ACC/ACP 604/6x7 Frequency Converters

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Chapter 3 – Electrical Installation

Mains, Motor and Control Cable Connection

A view of the recommended earthing, mains and motor cable connections of the ACx 607 (types -0320-3 and -0400-5/6 and smaller) is presented below. F denotes a 360 degrees earthing.
Max 6 control cables L1 L2 L3 PE 2)

ACx 607 Frequency Converter

F

F
U1 V1 W1

X2 (option)

EMC Line Filter NIOC/ NIOCP NAMC Line Options

PE

4) NIOC/ NIOCP NAMC ACx 604 Converter Unit UDC+ UDC-

U1 V1

W1 T41

U2

V2

W2

du/dt Filter Common Mode Filter 3)

F
1) used if the conductivity of the cable screen is < 50 % of the conductivity of the phase conductor. 2) used if the PE rail of the ACx 607 is not earthed via a separate PE conductor or via cable screen. 3) used only if local safety regulations do not accept earthing of the ACx 607 and the motor merely through the cable screen. Note: Connecting the fourth conductor of the cable at the motor increases bearing currents, thus causing extra wear. 4) The NIOC/NIOCP board is located inside the module in ACx 604 deliveries. U1 V1

F

1)

W1 For minimum radio frequency interference (RFI) at the motor end, earth the cable screen 360 degrees at the lead-through or earth the cable by twisting the screen (flattened width > 1/5 · length).

3

~

Motor

3-8

ACS/ACC/ACP 604/6x7 Frequency Converters

Chapter 3 – Electrical Installation

WARNING! This work should only be carried out by a qualified electrician. The Safety Instructions on the first pages of this manual must be followed. Negligence of these instructions can cause injury or death. Frame Sizes R7 to R9 The mains and motor cables connect to the ACx 607 in the left part of the cabinet. Mains, motor and control cable lead-through is from below or from above. To locate the terminals see the dimensional drawings (Appendix B). To connect the mains and motor cables to the ACx 607, carry out the following procedure. 1. Make sure that the ACx 607 is disconnected from the mains network during installation. Wait for 5 minutes if the ACx 607 is already connected to the mains after disconnecting mains power. 2. Open the cabinet door. 3. Open the hinged assembly plate to gain access to the mains and motor cable terminals. 4. Measure the voltage between each input terminal (U1, V1, W1) and earth with a multimeter (impedance at least 1 MW) to ensure that the frequency converter is discharged. 5. Lead the cables inside the cabinet through the EMC sleeves.
If cable entry is not possible otherwise, remove the lead-through plate and slide it onto the cable. After the earthing connections are done, fasten the lead-through plate. IP 54 and cable entry from above: Remove the rubber grommets from the lead-through plates and cut them to adequate diameter for the mains and the motor cable. To ensure proper sealing, cut along the diameter marking that corresponds to the cable diameter. Slide the grommet onto the cable.

Earthing Connections

6. Strip the cable according to the figure below. (For IP 54 units and cable entry from above, add a rubber grommet on the cable under/ above the lead-through plate.) 7. Tighten the EMC sleeve on the bare cable screen with cable ties. 8. Twist the screen wires together to a pigtail and connect to the PE terminal of the cabinet.

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Chapter 3 – Electrical Installation

Cable shield PE terminal Strain relief

EMC sleeve

Strip this part of the cable

Base plate Lead-through plate

9. Earth the other end of the mains cable screen at the distribution board. 10. Earth the motor cable screen 360 degrees on the motor side.
11. Connect the additional PE conductors (if present) of the mains and motor cables to the PE terminal of the cabinet. 12. Connect the separate PE conductor (if used) to the PE terminal of the cabinet.

3-10

ACS/ACC/ACP 604/6x7 Frequency Converters

Chapter 3 – Electrical Installation

Common Mode Filter

If common mode filter or light common mode filter is required (see Safety Instructions: Motor Connections / Requirements Table), lead the motor cable phase conductors through the toroidal cores as follows: 1. 2. Connect the twisted cable screen to the PE terminal. Wrap the phase conductors together with the silicon rubber tape delivered with the toroidal cores to provide thermal insulation for the conductor insulator. Cover the part of the cable which will be left inside the core(s) + 20 mm below. Approximately 1.5 metres of tape is needed per cable. Each turn must overlap the previous turn by half the width of the tape. Bind the conductors tightly with non-conductive electrical tape and a non-metallic cable tie in order to prevent conductor insulation damage caused by the core edges. Slide the core(s) onto the taped part of the phase conductors. Bind the cores together and onto the taped part of the phase conductors with heat-resisting non-metallic cable ties.

3.

4. 5.

2 3

1

5
Common Mode Filter Light Common Mode Filter

Code 64315439-B

ACS/ACC/ACP 604/6x7 Frequency Converters

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Chapter 3 – Electrical Installation

Mains and Motor Cable Connections

1. Connect the phase conductors of the mains cable to the U1, V1 and W1 terminals and the phase conductors of the motor cable to the U2, V2 and W2 terminals. 2. Check that the earthing is still OK. 3. Close the hinged assembly plate.

Transformer Settings

1. ACx 604/607 units (except frame R7 units) include a transformer (T41) which supplies power to the cooling fan at the base of the converter unit. The transformer is set to 415 V, 500 V or 690 V at the factory. Adjust the setting if it does not correspond to the supply voltage. To access the transformer remove the front cover of the converter unit with the ABB logo. After adjusting the voltage put the plate back into its place.

F1 F2

T41
500V 480V
460V

440V
415V

400V 380V

0

2. Cabinets with the line contactor option include an internal auxiliary voltage transformer. Its input voltage is set to 415 V, 500 V or 690 V at the factory. Adjust the setting if it does not correspond to the supply voltage. The transformer is located in the upper right part of the cabinet, and is visible when the cabinet door is opened.

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ACS/ACC/ACP 604/6x7 Frequency Converters

Chapter 3 – Electrical Installation

Types ACx 6x7-0400-3, -0490-5/6 and up (2 x R8 and 2 x R9)
Max 6 control cables

A detailed view of the recommended earthing, mains and motor cable connections of the ACx 6x7 parallel connected units is presented below. F denotes a 360 degrees earthing.
L1 L2 L3 PE 2)

F
ACx 607 Frequency Converter (2 x R8 and 2 x R9 units) X2

F
U1 V1 W1

EMC Line Filter

NIOC/NAMC Control Boards Line Options PE

U1

V1 W1 T41

U1 V1

W1 T41

ACx 604 Converter Unit U2 V2 W2

ACx 604 Converter Unit U2 V2 W2

du/dt Filter

du/dt Filter 3) U2 V2 W2

Common Mode Filter

F
1) used if the conductivity of the cable screen is < 50 % of the conductivity of the phase conductor 2) used if the PE rail of the ACx 607 is not earthed via a separate PE conductor or via cable screen. 3) used only if local safety regulations do not accept earthing of the ACx 600 and the motor merely through the cable screen. Note: Connecting the fourth conductor of the cable at the motor increases bearing currents, thus causing extra wear. V1

1)

U1

W1

3

~

Motor

ACS/ACC/ACP 604/6x7 Frequency Converters

3-13

Chapter 3 – Electrical Installation

To connect the mains and motor cables for ACx 6x7 frame sizes 2 x R8 and 2 x R9, carry out the following procedure: 1. Make sure that the ACx 6x7 is disconnected from the mains network during installation. The switch fuse (with handle in the front door) of the ACx 6x7 does not switch off power from the EMC Line Filter. Disconnect the ACx 6x7 with EMC Line Filter from the mains network at the distribution board. Wait for 5 minutes before working on the frequency converter, the motor or the motor cable. 2. Open the cabinet door. 3. If EMC Line Filter is used, check that there is no voltage in its output terminals: measure the voltage from one terminal against the two other terminals and from terminal to earth. 4. Remove the emission shields and shrouds. 5. Go to point 5 on page 3-9. Connect the earthing, common mode filter, mains and motor cables. Transformer Settings 1. Both converter units include a transformer (designation T41) which supplies the cooling fan at the base of the unit (as well as the mains fuse supervision function). On each converter unit, remove the front cover plate and verify that the transformer is set to the correct supply voltage. 2. Both the left-hand and right-hand cabinets include an auxiliary voltage transformer, designated T21 and T10 respectively (pointed out in Appendix C). Verify that these transformers are set to the correct supply voltage. Mains Fuse Supervision The mains fuse supervision function uses the outputs of transformers T21 (LH cabinet), T10 (RH cabinet), and T41 (inside each converter unit) for detecting mains fuse failure. The fuse condition information is wired to terminal block X3, and further to the main contactors (if present). The internal earth fault protective function is not in use in 12-pulse supplied ACx 627 units. Earth fault detection is implemented by means of a separate unit, wired to terminal block X3, and further to the main contactors (if present). On units not equipped with main contactors, additional wiring by the commissioner is required for activation of the mains fuse supervision and ACx 627 earth fault detection functions. It is recommended that these functions be wired to switch off the mains supply should a fuse failure or an earth fault occur. Refer to the circuit diagrams (Sheet 50) supplied with the unit.

ACx 627 Earth Fault Detection

Note:

3-14

ACS/ACC/ACP 604/6x7 Frequency Converters

Chapter 3 – Electrical Installation

Control Cable Connecting Procedure

To connect the control cables for the ACx 6x7 carry out the following procedure:
Side view Top view

Lead-through plate EMI conductive cushions

Holes for position screws Base plate

Special for Top Entry

When each cable has its own rubber grommet, sufficient IP and EMC protection can be achieved. However, if very many control cables come to one cabinet, plan the installation beforehand as follows: 1. Make a list of the cables coming to the cabinet. 2. Sort the cables going to the left into one group and the cables going to the right into another group to avoid unnecessary crossing of cables inside the cabinet. 3. Sort the cables in each group according to size. 4. Group the cables for each grommet as follows:
Cable diameter in mm < 13 < 17 < 25 > 25 Max. number of cables per grommet 4 3 2 1

ACS/ACC/ACP 604/6x7 Frequency Converters

3-15

Chapter 3 – Electrical Installation

5. Divide the bunches so that the cables will be arranged according to size between the EMI conductive cushions.
View from below

Thinnest cable

Thickest cable

Bottom and Top Entry

Proceed as follows: 1. Loosen the lead-through plate position screws. Pull the two parts apart. 2. Bottom entry Lead the cable inside the cabinet through the EMI conductive cushions. Top entry Lead the cable inside the cabinet through the grommet and the EMI conductive cushions. If you have several cables, bunch them together at the grommet, but ensure that each cable has a proper contact to the cushions on both sides. 3. Strip off the cable plastic sheath above the base plate (only a distance wide enough to ensure proper connection of the bare screen and the EMI conductive cushions). 4. Earth the screen between the EMI conductive cushions: a. If the outer surface of the screen is conductive: - Push the two parts of the lead-through plate together so that the EMI conductive cushions press tightly round the bare screen.

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ACS/ACC/ACP 604/6x7 Frequency Converters

Chapter 3 – Electrical Installation

b. If the outer surface of the screen is covered with non-conductive material:
Stripped cable Conductive surface of the screen exposed Stripped part covered with copper foil

Copper foil Cable screen Screened twisted pair Earthing wire

- Cut the screen at the midpoint of the bare part. Be careful not to cut the conductors. - Turn the screen inside out to expose its conductive surface. - Cover the turned screen and the stripped cable with copper foil to keep the shielding continuous. Note: The earthing wire (if present) must not be cut. - Push the two parts of the lead-through plate together such that the EMI conductive cushions press tightly round the foil-covered screen. 5. Lock the two parts of the lead-through plate by tightening the positioning screws.

ACS/ACC/ACP 604/6x7 Frequency Converters

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Chapter 3 – Electrical Installation

6. Top entry: If more than one cable go through a grommet, the grommet must be sealed by Loctite 5221 (catalogue number 25551).
Side view

Apply Loctite 5221 inside the grommet.

Attach control cables to the supporting plate.

Connect the earthing wire to the PE busbar.

7. Connect the control cables in appropriate terminal to NIOC/NIOCP board (or optional terminal block X2/2TB, or other options on the DIN rail). Refer to Appendix A and Firmware Manual. Tighten screw to secure connection. Connect the twisted screen (as short as possible) to the earthing rail of the terminal. 8. Close the cabinet door if no other cables are to be connected.

3-18

ACS/ACC/ACP 604/6x7 Frequency Converters

Chapter 3 – Electrical Installation

Control Panel in Remote Use

Connect the Control Panel cable to terminal X19 of the NAMC-11/51, or with the NAMC-03 board to terminal X28 of the NIOC board (X300 of the NIOCP board).
ACx 601/604 with NAMC-11/51 board Panel cable with screened connectors (metal enclosure)

with NAMC-03

NIOC X28

NAMC-11/51 with NDCO NAMC-11/51 X19 X19

Earth the cable screen at the near earthing screw.
NAMC-11/51 X19 X300 NIOCP board

Pulse Encoder Insulation (ACP 600)

The pulse encoder shall be insulated electrically from the stator or the rotor to prevent forming of a current path through the pulse encoder. The usual coupling-type encoder must have an electrically insulating coupling. When a hollow-shaft type pulse encoder is used, the insulation can be implemented by insulating the ball joints of the engaging arm, or insulating the bar of the engaging arm. Shield of the encoder cable should be insulated from the encoder frame. When the encoder is connected correctly, running the drive in the Forward (positive) direction should produce positive encoder feedback. On incremental encoders, the two output channels, usually marked 1 and 2 or A and B, are 90° (electrical) apart from each other. When rotated clockwise, most encoders – but not all – have channel 1 leading channel 2. Determine the leading channel by referring to the encoder documentation, or by measuring with an oscilloscope. The encoder output channel that leads when the drive runs Forward should be connected to NIOCP input A, the output channel that trails to NIOCP input B. The zero reference output channel is connected to NIOCP input Z.

Pulse Encoder Phasing (ACP 600, NIOCP Board)

ACS/ACC/ACP 604/6x7 Frequency Converters

3-19

Chapter 3 – Electrical Installation

Installation of Optional Modules and DriveWindow
Placement

This section gives general installation instructions for DriveWindow PC tool and ACx 600 optional modules, such as fieldbus adapters, I/O extension modules and the pulse encoder interface. Connection examples are given at the end of the section. The module should be installed on the DIN mounting rail inside the cabinet. Follow the instructions given in the Mechanical Installation chapter of the module manual. The 24 V d.c. supply for one optional module is provided by the NIOC/ NIOCP board of the converter (NIOC: terminal X23, NIOCP: terminal X4). The location of the NIOC/NIOCP board is shown in the dimensional drawings (Appendix B). Optional modules are connected via a DDCS fibre optic link to the NAMC board or NDCO board (both mounted on top of the NIOC board). The terminals on the NAMC/NDCO board to which the cables are connected are given in the table below. Channel CH1 is on the NAMC-11/51 board. Channels CH0, CH2 and CH3 are on the NDCO board. NAMC-3 board includes channels CH0 to CH3.
Module Type Fieldbus Adapter Modules I/O Extension Modules Pulse Encoder Interface Module Channel CH0* CH1 CH2* with ACS 600 Standard Application Program 5.x/6.x CH1 with ACS 600 System, Crane Master/Follower and Template Application Program Double Pulse Encoder Interface Module (for ACP 600 only) DriveWindow CH2* CH3* Terminals V13*, V14* V15, V16 V17*, V18*

Power Supply for the Module

Fibre Optic Link

V15, V16

V17*, V18* V19*, V20*

* on NDCO board when NAMC-11/51 board is used.
1)

DriveWindow Light is connected via an NPCU RS-232/485 converter to the panel connector on the cover (or to modular jack X19 on the NAMC-11/51 board).

Observe colouring codes when installing fibre optic cables. Blue connectors should go to blue terminals, and grey connectors to grey terminals. In case multiple modules are installed on the same channel, they must be connected in a ring.

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ACS/ACC/ACP 604/6x7 Frequency Converters

Chapter 3 – Electrical Installation

Connection Examples
Fieldbus Adapter Module ACx 600 NAMC
CH1 T R
RXD TXD

NIOC/ NIOCP

CH0 T R

NDCO

T R

NIOC Terminal X23 NIOCP Terminal X4

The terminals for the power supply connection vary. Consult adapter module manual.

I/O Extension Module ACx 600 Pulse Encoder Module with ACS 600 Crane, System, Master/Follower and Template Application Programs
CH1 T R

NAMC NDCO T R

NIOC

RXD TXD

NIOC Terminal X23

The terminals for the power supply connection vary. Consult module manual.

Not supported by ACP 600

ACS/ACC/ACP 604/6x7 Frequency Converters

3-21

Chapter 3 – Electrical Installation

Connection Examples

Pulse Encoder Module (NTAC) with ACS 600 Standard Application Program

ACS 600* NAMC
CH2 T R CH1 T R

NIOC

NDCO T R

RXD TXD

NIOC Terminal X23

The terminals for the power supply connection vary. Consult module manual.

* The ACP 600 supports the NTACP Double Pulse Encoder instead. See NTACP Installation and Start-up Guide.

DriveWindow ACx 600 NAMC
CH3 T R CH1 T R R

NIOC/ NIOCP

NDCO T R

Laptop PC

R T

R T

NDPC NDPA

NISA Desktop PC

3-22

ACS/ACC/ACP 604/6x7 Frequency Converters

Chapter 3 – Electrical Installation

Installation of Other Optional Equipment

Install options such as PTC/PT100 relays, cubicle heater, motor fan starter etc. according to circuit diagrams delivered with the unit.

ACS/ACC/ACP 604/6x7 Frequency Converters

3-23

Chapter 3 – Electrical Installation

3-24

ACS/ACC/ACP 604/6x7 Frequency Converters

Chapter 4 – Installation Checklist

Installation Checklist

The ACx 600 mechanical and electrical installation should be checked before start-up. It is advisable to go through the checklist below together with another person. Study carefully the Safety Instructions on the first pages of this manual before attempting any work on, or with, the unit.

INSTALLATION CHECKLIST
MECHANICAL INSTALLATION Check that the ambient operating conditions are allowable. (See Appendix A: environmental limits, cooling air flow requirements, free space requirements) Check that the unit is fixed properly. (See Chapter 2 – Mechanical Installation) Check that cooling air flows freely. Check the applicability of the motor and the driven equipment. (See Appendix A: Motor Connection) ELECTRICAL INSTALLATION (see Chapter 3 – Electrical Installation) If the ACx 600 is connected to unearthed mains, check that the EMC filter capacitors are disconnected. Check that the converter unit is earthed properly. Check that the mains voltage matches the frequency converter nominal input voltage. In the ACx 607 (except frame R7) and the ACx 604, check that the setting of the transformer T41 corresponds to the supply voltage. In ACx 6x7 types -0400-3 and -0490-5/6 and up, check that the settings of the transformers T21 and T10 correspond to the supply voltage. With line contactor option, check that the setting of the internal transformer corresponds to the supply voltage. Check that mains connections at U1, V1 and W1 are OK. Check that appropriate mains fuses are installed. Check that toroidal cores are properly installed on the motor cable when common mode filter is required.

ACS/ACC/ACP 604/6x7 Frequency Converters

4-1

Chapter 4 – Installation Checklist

INSTALLATION CHECKLIST
Check that motor connections at U2, V2 and W2 are OK. Check motor cable routing. Check that there are no power factor compensation capacitors in the motor cable. Check that control connections inside the frame are OK. Check that options such as PTC/PT100 relays, cubicle heater, motor fan starter etc. are wired inside the cabinet. See the circuit diagrams delivered with the unit. In ACx 627 types -0400-3 and -0490-5/6 and up not equipped with main contactors, check the wiring for switching off the mains supply in case of a fuse failure and an earth fault. See Safety Instructions. Check that there are no tools or other foreign objects inside the cabinet. With bypass connection, check that mains voltage cannot be applied to the output of the ACx 600.

4-2

ACS/ACC/ACP 604/6x7 Frequency Converters

Chapter 5 – Maintenance

WARNING! All maintenance work described in this chapter must be undertaken by a qualified electrician only. The Safety Instructions on the first pages of this manual must be followed.

Heatsink

The ACx 600 can run into overtemperature Faults if the heatsink is not clean. In normal environment, the heatsink should be checked and cleaned annually. Use compressed air to remove dust from the heatsink. (The airflow direction must be from bottom to top.) Also, use a vacuum cleaner at the air outlet to trap the dust. Fan rotation must be prevented in order to prevent bearing wear.

Fan

The cooling fan lifespan is about 60 000 hours (R7) or 30 000 hours (R8 and R9). The actual lifespan depends on the frequency converter usage and ambient temperature. Fan failure is often preceded by increasing noise from fan bearings and gradual rise of the heatsink temperature (in spite of heatsink cleaning). If the frequency converter is operated in a critical part of a process, fan replacement is recommended once these symptoms start appearing.

Capacitors

The ACx 600 intermediate circuit employs several electrolytic capacitors. Their lifespan is about 100 000 hours. It depends on the frequency converter loading and the ambient temperature. Capacitor life can be prolonged by lowering the ambient temperature. It is not possible to predict capacitor failure. Capacitor failure is usually followed by a mains fuse failure or a Fault trip. Contact ABB if capacitor failure is suspected. Replacements are available from ABB. Do not attempt operation with other than ABB specified spare parts. Reforming Converter DC link capacitors need to be reformed (re-aged) if the converter has been non-operational for more than one year. Without reforming capacitors may be damaged when the converter starts to operate. The reforming methods introduced here require that the converter has been stocked clean and dry. It is recommended to reform the capacitors once a year.

ACS/ACC/ACP 604/6x7 Frequency Converters

5-1

Chapter 5 – Maintenance

How to check the converter age

Converter serial number defines the week, when the converter has been built: ? 8 digit: e.g. 18250125, 1 denotes manufacturing country (1 = Finland), 8 manufacturing year (1998), 25 manufacturing week and 0125 running manufacturing number. ? 10 digit: e.g. 1983200725, 1 denotes manufacturing country, 98 manufacturing year, 32 manufacturing week and 00725 running manufacturing number.

Reforming time

The intermediate circuit of the converter is kept in its nominal voltage for the reforming time to “wake up” the capacitors. The reforming time required depends on how long the converter has been stocked (nonoperational).
Reforming time (hours) 6 5 4 3 2 1 0 0 1 Method 1 2 3 5 4 6 Non-operational time (years) Method 2

Figure 5-1. Capacitor reforming time for Method 1 and Method 2. Converters Stocked (Nonoperational) for Less Than 2 years Switch the power on to the converter for a time given in Figure 5-1 (Method 1). The converter “wakes up” its capacitors by itself. Power the converters up once a year to keep the capacitors in operational condition. Use Method 2 A or Method 2 B (both explained below) for capacitor reforming if the converter has been stocked or non-operational for two or more years. WARNING! The ACx 6x7 inverters must be reformed outside the cabinet.

Converters Stocked (Nonoperational) for 2 Years and Over

5-2

ACS/ACC/ACP 604/6x7 Frequency Converters

Chapter 5 – Maintenance

Method 2 A

Capacitor reforming is realised by connecting a rectifier and a resistor circuit to the converter DC link. The reforming circuit and component values for different voltages are given below. See the reforming time from Figure 5-1. WARNING! The converter supply must be disconnected while the reforming circuit is connected.

U1

A

C R L– L+

Disconnect from supply (1.35 ×U1)

W2 V2 U2

Converter

Supply Voltage A 380 V < U1 < 415 V 380 V < U1 < 500 V 525 V < U1 < 690 V SKD 82/16 SKD 82/16 SKD 82/16

Recommended Components R 220 Ohm / 700 W 470 Ohm / 1200 W 680 Ohm / 1700 W C 22 nF / 2000 V 22 nF / 2000 V 22 nF / 2000 V

ACS/ACC/ACP 604/6x7 Frequency Converters

5-3

Chapter 5 – Maintenance

Method 2 B

Capacitor reforming is based on a DC power supply connected to converter DC link. Power supply current charges converter capacitors. If power supply cannot limit the current, voltage is increased gradually (with e.g. 100 V steps). Maximum recommended reforming current is 500 mA. An appropriate reforming voltage is (1.35... ?2) × U1. The reforming circuit is shown below. See reforming time from Figure 5-1. WARNING! The converter supply must be disconnected while the reforming circuit is connected.

DC Power Supply R* L– L+

Disconnect from supply (1.35 ×U1)

W2 V2 U2

Converter

* R = 100 Ohm / 500 W

5-4

ACS/ACC/ACP 604/6x7 Frequency Converters

Chapter 5 – Maintenance

Control Panel Connection

The Control Panel is connected to modular jack X19 on NAMC-11/51 board. The modular jacks on the NIOC board are not intended for Panel use (they are used by Standard Modbus Link).

CH3

CH2

CH1

CH0

INT

BRC

NDCO-0x
(Component Side Down)

Spacer

X3*

X1

Spacer

X19

NAMC-11/51
V16 V15 V12 V11

* on NAMC-51 for optional Memory Backup board (NMBO)

LEDs

The table below shows the indications of the LEDs on the control boards.
Control Board NAMC LED Green V4 Red V18 Red V5 (not in use) NINT NIOC Green V14 Green V5 Red V6 NPOW Green V4 When the LED is lit The power supply of the board is OK. Fault – The board is powered. The power supply of the board is OK. Fault The board is powered.

ACS/ACC/ACP 604/6x7 Frequency Converters

5-5

Chapter 5 – Maintenance

5-6

ACS/ACC/ACP 604/6x7 Frequency Converters

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

IEC Ratings

The IEC ratings for ACx 604 and ACx 6x7 with 50 Hz and 60 Hz supplies are below. ACx = ACS/ACC/ACP. The 690 V series and 2 x R8 and 2 x R9 frame sizes are not available for ACP 600. See the next page for symbols.
Normal Use Heavy-duty Use Duty Cycle 1/5 min SN [kVA] PN [kW] PN [HP] 100 125 150 200 250 300 350 400 500 600
4/5min 1/5min

Frequency Converter Type

Duty Cycle 1/5 min I2N
4/5min

Duty Cycle 1) 2/15 s Phd [kW] 55 75 90 110 132 160 200 250 315 400 75 90 110 132 160 200 250 315 400 500 55 75 90 110 132 160 200 250 315 400 500 Phd [HP] 75 100 125 150 200 250 300 350 400 500 75 100 125 150 200 250 300 400 500 600 75 100 125 150 150 200 250 300 350 450 500
13/15s 2/15s

I2Nmax
1/5min

I2hd I2hdmax I2hd I2hdmax Shd [A] 112 147 178 216 260 316 395 494 600 751 [A] 168 221 267 324 390 474 593 741 901 1127 [A] 112 147 178 216 260 316 395 494 600 751 [A] 224 294 356 432 520 632 790 988 1200 1502 224 270 328 400 480 600 730 912 1140 1388 98 132 158 191 225 269 338 398 510 642 756 [kVA] 70 100 120 140 170 210 260 320 400 490 100 120 140 170 210 260 320 400 490 610 70 100 120 140 170 210 260 320 400 490 610

Frame Size

[A]

[A]

Three-phase supply voltage 380 V, 400 V or 415 V ACx 604/607-0100-3 147 162 100 75 ACx 604/607-0120-3 178 196 120 90 ACx 604/607-0140-3 216 238 140 110 ACx 604/607-0170-3 260 286 170 132 ACx 604/607-0210-3 316 348 210 160 ACx 604/607-0260-3 395 435 260 200 ACx 604/607-0320-3 480 528 320 250 ACx 604/6x7-0400-3 600 661 400 315 ACx 604/6x7-0490-3 751 827 490 400 ACx 604/6x7-0610-3 912 1003 610 500

R7 R8 R9 2xR8 2xR9

Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V ACx 604/607-0120-5 135 149 120 90 100 112 168 112 ACx 604/607-0140-5 164 180 140 110 125 135 203 135 ACx 604/607-0170-5 200 220 170 132 150 164 246 164 ACx 604/607-0210-5 240 264 210 160 200 200 300 200 ACx 604/607-0260-5 300 330 260 200 250 240 360 240 ACx 604/607-0320-5 365 402 320 250 300 300 450 300 ACx 604/607-0400-5 460 506 400 315 350 365 548 365 ACx 604/6x7-0490-5 570 627 490 400 500 456 684 456 ACx 604/6x7-0610-5 694 764 610 500 600 570 855 570 ACx 604/6x7-0760-5 874 961 760 630 700 694 1041 694 Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V ACx 604/607-0100-6 88 97 100 75 100 65 98 ACx 604/607-0120-6 105 116 120 90 125 88 132 ACx 604/607-0140-6 127 140 140 110 150 105 158 ACx 604/607-0170-6 150 165 170 132 150 127 191 ACx 604/607-0210-6 179 197 210 160 200 150 225 ACx 604/607-0260-6 225 248 260 200 250 179 269 ACx 604/607-0320-6 265 292 320 250 300 225 338 ACx 604/607-0400-6 351 386 400 315 350 265 398 ACx 604/6x7-0490-6 428 470 490 400 450 340 511 ACx 604/6x7-0610-6 504 555 610 500 500 428 642 ACx 604/6x7-0760-6 667 734 760 630 700 504 756 65 88 105 127 150 179 225 265 340 428 504

R7 R8 R9 2xR8 2xR9

R7 R8

R9 2 x R8 2 x R9

ACS/ACC/ACP 604/6x7 Frequency Converters

A-1

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

Pump and Fan Use (Squared Load) ACS 604/607 Type I2Nsq [A] PN [kW] Frame Size

The current ratings are the same regardless of the supply voltage within one voltage range. The rated current of the ACx 60x must be higher than or equal to the rated motor current to achieve the rated motor power given in the table. Note 1: The maximum allowed motor shaft power is limited to 1.5 · Phd. If the limit are exceeded, the motor torque and the I2hdmax 2/15 s current is automatically restricted. The function protects the input bridge of the ACS 600 against overload. Note 2: The load capacity (current and power) decreases if the installation site altitude exceeds 1000 metres, or if the ambient temperature exceeds 40 °C (or 35 °C with ACx 60x-0120-03 and ACx 60x-0140-05 units in Pump and Fan Use). See Output Current Temperature Derating on page A-3. Note 3: The Pump and Fan rating is not to be used with du/dt filters. du/dt filters are usually needed at the output of 525 V to 690 V units with random-wound motors. No du/dt filters are usually required with form-wound motors. Notes concerning Pump and Fan Use only Pump and Fan rating is available for ACS 600 with Standard and Pump and Fan Control Application Programs. ( ) typically achieved motor power with I2Nsq

Three-phase supply voltage 380 V, 400 V or 415 V ACS 604/607-0100-3 178 90 R7 ACS 604/607-0120-3 200 110 (100) ACS 604/607-0140-3 260 132 R8 ACS 604/607-0170-3 300 160 ACS 604/607-0210-3 375 200 ACS 604/607-0260-3 480 250 R9 ACS 604/607-0320-3 510 315 (265) ACS 6x4/6x7-0400-3 712 400 2xR8 ACS 6x4/6x7-0490-3 912 500 2xR9 ACS 6x4/6x7-0610-3 969 560 Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V ACS 604/607-0120-5 164 110 R7 ACS 604/607-0140-5 193 132 ACS 604/607-0170-5 240 160 R8 ACS 604/607-0210-5 285 200 ACS 604/607-0260-5 345 250 ACS 604/607-0320-5 460 315 R9 ACS 604/607-0400-5 490 400 (335) ACS 6x4/6x7-0490-5 656 450 2xR8 ACS 6x4/6x7-0610-5 874 630 2xR9 ACS 6x4/6x7-0760-5 990 710

Normal use (10 % overload capacity): rated rms output current I2N I2Nmax rms overload current (allowed for one minute every 5 minutes): I2Nmax (1/5 min) = 1.1 · I2N

SN PN

rated apparent output power typical motor power. The power ratings in kW apply to most IEC 34 motors. The power ratings in HP apply to most four pole NEMA rated motors.

Heavy-duty use (50 % or 100 % overload capacity): I2hd rated rms output current I2hdmax rms overload current (allowed for one minute every 5 minutes or 2 seconds every 15 seconds). Maximum current depends on parameter setting, refer to Firmware Manual. I2hdmax (1/5 min) = 1.5 · I2hd I2hdmax (2/15 s) = 2.0 · I2hd (400 and 500 VAC units) or 1.5 · I2hd (690 VAC units) Shd rated apparent output power Phd typical motor power. The power ratings in kW apply to most IEC 34 motors. The power ratings in HP apply to most four pole NEMA rated motors.

Pump and Fan Use (Squared Load): no overload capacity rated rms output current I2Nsq

A-2

ACS/ACC/ACP 604/6x7 Frequency Converters

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

NEMA Ratings

The NEMA ratings for ACS 604 and ACS 607 with 60 Hz supply are below. Symbols are described on the previous page.
Normal Use Duty Cycle 1/5 min I2N
4/5min

Heavy-duty Use Duty Cycle 1/5 min PN
4/5min 1/5min

ACS 604/607 Type

Duty Cycle 1) 2/15 s
13/15s 2/15s

I2Nmax
1/5min

I2hd I2hdmax I2hd I2hdmax Phd [A] [A] [A] [A] [HP]

Frame Size

[A]

[A]

[HP]

Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V ACS 604/607-0120-4 156 172 125 113 168 113 224 75 ACS 604/607-0140-4 180 198 150 141 203 141 270 100 ACS 604/607-0170-4 216 238 150 172 246 172 328 125 ACS 604/607-0210-4 260 286 200 200 300 200 400 150 ACS 604/607-0260-4 316 348 250 240 360 240 480 200 ACS 604/607-0320-4 414 455 300/350 300 450 300 600 250 ACS 604/607-0400-4 480 528 400 365 548 365 730 300

R7 R8 R9

Note: The US manufactured units are labelled to -4 types. The information in this manual concerning the corresponding -5 type applies to them.

Output Current Temperature Derating

The output current is calculated by multiplying the current given in the rating table by the derating factor. Temperature derating factor for ACx 6x7: ? General rule: Above +40 °C / +104 °F (+35 °C / +95 °F for types ACS 60x-0120-03 and ACS 60x-0140-5 with I2Nsq rating), the rated output current is decreased by 1.5 % for every additional 1 °C / 1.8 °F (up to +50 °C / +122 °F). This applies to I2N and I2Nsq (for I2hd no derating is needed). ? Example 1. If the ambient temperature is 50 °C / +122 °F the derating factor is 100 % - 1.5 % · 10 °C = 85 % or 0.85.
°C

The output current is then 0.85 · I2N or 0.85 · I2Nsq or 1 · I2hd.

ACS/ACC/ACP 604/6x7 Frequency Converters

A-3

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

Input Power Connection

Voltage (U1): 380/400/415 VAC 3-phase ± 10 % for 400 VAC units 380/400/415/440/460/480/500 VAC 3-phase ± 10 % for 500 VAC units 525/550/575/600/660/690 VAC 3-phase ± 10 % for 690 VAC units Short Circuit Capability: The rated short-time withstand current of the ACx 600 is 50 kA 1 s.
Measured according to US standards up to 400 kVA: Suitable for use in a circuit capable of delivering not more than 65 kA rms symmetrical amperes at 480 V maximum (500 V units), and at 600 V maximum (690 V units).

Frequency: 48 to 63 Hz, maximum rate of change 17 %/s Imbalance: Max. ± 3 % of nominal phase to phase input voltage Fundamental Power Factor (cos j1): 0.97 (at nominal load)

Motor Connection

Voltage (U2): 0 to U1, 3-phase symmetrical Frequency: DTC mode: 0 to 3.2 · fFWP . Maximum frequency 300 Hz.
fFWP = UNmains UNmotor · fNmotor

fFWP: Frequency at field weakening point; UNmains: Mains (input power) voltage; UNmotor: Rated motor voltage; fNmotor: Rated motor frequency

Scalar Control mode (not for ACP 600): 0 to 300 Hz With du/dt Filter (DTC and Scalar Control modes): 0 to 120 Hz Frequency Resolution: 0.01 Hz Current: see rating tables Power Limit: 1.5 · Phd Overcurrent Trip: 3.5 · I2hd Field Weakening Point: 8 to 300 Hz Switching Frequency: 3 kHz (average). In 690 V units 2 kHz (average). Maximum Recommended Motor Cable Length: 300 m (980 ft). This is the cumulative length in case of parallel connected motors. For ACx 601-0005-3 to ACx 601-0016-3, ACx 601-0006-5 to ACx 601-0020-5 and ACx 601-0009-6 to ACx 601-0020-6, if the motor cable length exceeds 70 metres (230 ft), an ABB representative should be consulted. Bearings of over 90 kW (125 HP) Motors: Insulated bearing at nondriven end is recommended.

A-4

ACS/ACC/ACP 604/6x7 Frequency Converters

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

Efficiency and Cooling Ambient Conditions

Efficiency: Approximately 98 % at nominal power level Cooling Method: Internal fan, flow direction from the bottom to the top Environmental limits of the ACS/ACS/ACP 600 frequency converters are given below. The frequency converters are to be used in a heated, indoor, controlled environment.
Storage in the protective package Transportation in the protective package -

ACS/ACC/ACP 600 Installation Site Altitude Air Temperature

Operation installed for stationary use Nominal output power at 0 to 1000 m (3300 ft) above sea level 1) 0 to +40 °C (32 to 104°F)2) (IP 21/22 and ACx 607, IP 54) 0 to +25 °C (32 to 77°F) 2) (ACx 601, IP 54) 5 to 95%

-40 to +70 °C (-40 to +158°F)

-40 to +70 °C (-40 to +158°F)

Relative Humidity

Max. 95%

Max. 95%

No condensation allowed. Maximum allowed relative humidity is 60% in the presence of corrosive gases. Contamination Levels (IEC 721-3-3) No conductive dust allowed. Boards without coating: Chemical gases: Class 3C1 Solid particles: Class 3S2 Boards with coating: Chemical gases: Class 3C2 Solid particles: Class 3S2 Atmospheric Pressure Vibration (IEC 68-2-6) 70 to 106 kPa 0.7 to 1.05 atmospheres Max. 0.3 mm (0.01 in.) (2 to 9 Hz), max. 1 m/s2 (3.3 ft./s2) (9 to 200 Hz) sinusoidal Not allowed Not allowed Boards without coating: Chemical gases: Class 1C2 Solid particles: Class 1S3 Boards with coating: Chemical gases: Class 1C2 Solid particles: Class 1S3 70 to 106 kPa 0.7 to 1.05 atmospheres Max. 1.5 mm (0.06 in.) (2 to 9 Hz), max. 5 m/s2 (16.4 ft./s2) (9 to 200 Hz) sinusoidal Max. 100 m/s2 (330 ft./s2), 11 ms 250 mm (10 in.) for weight under 100 kg (220 lbs.) 100 mm (4 in.) for weight over 100 kg (220 lbs.) Boards without coating: Chemical gases: Class 2C2 Solid particles: Class 2S2 Boards with coating: Chemical gases: Class 2C2 Solid particles: Class 2S2 60 to 106 kPa 0.6 to 1.05 atmospheres Max. 3.5 mm (0.14 in.) (2 to 9 Hz), max. 15 m/s2 (49 ft./s2) (9 to 200 Hz) sinusoidal Max. 100 m/s2 (330 ft./s2), 11 ms 250 mm (10 in.) for weight under 100 kg (220 lbs.) 100 mm (4 in.) for weight over 100 kg (220 lbs.)

Shock (IEC 68-2-29) Free Fall

1)

At sites over 1000 m (3300 ft.) above sea level, the maximum output current is derated 1% for every additional 100 m (330 ft.). If the installation site is higher than 2000 m (6600 ft.) above sea level, please contact your local ABB distributor or office for further information.
2)

See subsection Output Current Temperature Derating.

Fuses

The input fuse ratings of the ACS/ACC/ACP 6x7 and recommended input fuse ratings of the ACS/ACC/ACP 604 are presented below. A minimum rated current in amperes, A2s maximum I2t value, V rated voltage in volts. Only ultra rapid fuses guarantee proper protection for the rectifier semiconductors.

ACS/ACC/ACP 604/6x7 Frequency Converters

A-5

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

.
Fuses
ACx 604/6x7 Types

Type DIN 43620 A A2s V Manufacturer Size

Type DIN 43653 Size

ACx 60x-0100-3 ACx 60x-0120-5 ACx 60x-0120-3 ACx 60x-0140-5 ACx 60x-0140-3 ACx 60x-0170-5 ACx 60x-0170-3 ACx 60x-0210-5 ACx 60x-0210-3 ACx 60x-0260-5 ACx 6xx-0400-3 ACx 6xx-0490-5 ACx 60x-0260-3 ACx 60x-0320-5 ACx 6xx-0490-3 ACx 6xx-0610-5 ACx 60x-0320-3 ACx 60x-0400-5 ACx 6xx-0610-3 ACx 6xx-0760-5 ACx 60x-0100-6 ACx 60x-0120-6 ACx 60x-0140-6 ACx 60x-0170-6 ACx 60x-0210-6 ACx 60x-0260-6 ACx 60x-0320-6 ACx 60x-0400-6 ACx 6xx-0490-6 ACx 6xx-0610-6 ACx 6xx-0760-6
1)

400

105000

660

Bussmann

170M3819

1*

170M3019

1*

550 700

190000 405000

690 660

Bussmann Bussmann

170M5811 170M5813

2 2

170M5011 170M5013

2 2

800

465000

660

Bussmann

170M6812

3

170M6012

3

125 200 250 315 400 550 400 550

8500 15000/ 28000 28500 46500 105000 190000 105000 190000

660 660 690 660 660 690 660 690

Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann

170M1568 170M3815/ 170M1570 170M3816 170M3817 170M3819 170M5811 170M3819 170M5811

000 1*/ 000 1* 1* 1* 2 1* 2

170M1368 170M1370 170M1370 170M3016 170M3017 170M3019 170M5011 170M3019 170M5011

000 000 000 1* 1* 1* 2 1* 2

Note: Fuses from other manufacturers can be used if they meet the ratings given in the table. Only ultra rapid fuses guarantee proper protection for the rectifier semiconductors. The fuses recommended in the table are UL R/C (JFRHRZ) fuses.
1)

15000 A2s and 28000 A2s Bussmann fuses can be used with the ACx 60x-0120-6.

A-6

ACS/ACC/ACP 604/6x7 Frequency Converters

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data
Example For ACS 604-0260-3, the recommended fuses for the input bridge protection are 700 A ultrarapid fuses. The values I2N, I2hd and I2Nsq for ACS 604-0260-3 are 395 A, 316 A and 480 A respectively. 1.1 · 395 A = 434.5 A and 1.5 · 316 A = 474 A and 1.0 · 480 A = 480 A. Normal fuses with nominal currents higher than 434.5 A, 474 A or 480 A can be used to protect the input cable; thus, 450 A or 500 A fuses are selected depending on the use (normal, heavy-duty or pump and fan, respectively).

Cable Entries

Input power and motor cable terminal wire size capabilities and tightening torques for the ACS/ACC/ACP 604/6x7 are in the table below. The capability is specified based on wire lug that the terminal accepts (according to DIN 46234 for copper cables and DIN 46329 for aluminium cables), cable cross section that will fit through the European lead-through plate hole, and maximum electrically needed European cable cross section. NEMA two hole lugs (1/2 inch in diameter and 1.75 inches on center) can be used in frame sizes R8 and R9 and R7 output.

Terms used ? Terminal kit (crush-down) connection. This kit is used in frame size R7 frequency converters (input cable terminal) and includes screws. The conductor is plugged into the kit without a cable lug. 1X120 Maximum cable cross section in mm2 Maximum number of cable connections ? Bus bar connection with hole requiring bolt, washer, nut, and wire lug to be supplied by others. The other style connection using the same reference is an insulated stud connection, washer and nut. The wire lug is provided by others. 1X(10-120) Maximum cable cross section in mm2 Diameter of maximum bolt that will fit through the hole in the bus bar, or stud connection in mm Maximum number of cable connections

? If an M is added before the number in the table (e.g. M10) we have a designator for a standard metric screw. Substitution Metric to US Standard
M8 - 5/16 inch diameter bolt M10 - 3/8 inch diameter bolt M12 - 1/2 inch diameter bolt

? T = Tightening torque.

ACS/ACC/ACP 604/6x7 Frequency Converters

A-7

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

Terminal Sizes and Tightening Torques

Input power and motor cable terminal wire size capabilities (per phase) and tightening torques for the ACS/ACC/ACP 604/6x7 are below. For terms used see above.
Mains Terminals Motor Terminals T Al 1x185 3) 1x120 3) 1x185
3)

Earthing Terminals T T Nm

ACx 600 Type Cu

U1,V1,W1

U2,V2,W2 Cu Al

Frame Size

Nm

Earthing PE

ACx 607-0100-3/0120-5 ACx 607-0100-6 ACx 607-0120-3/0140-5/0120-6 ACx 607-0140-3/0170-5/0140-6 ACx 607-0170-3/0210-5/0170-6 ACx 607-0210-3/0260-5/0210-6 ACx 607-00260-6 ACx 607-0260-3/0320-5/0320-6 ACx 607-0320-3/0400-5/0400-6 ACx 6x7-0400-3/0490-5/0490-6 ACx 6x7-0490-3/0610-5/0610-6 ACx 6x7-0610-3/0760-5/0760-6 ACx 604-0100-3/0120-5/0100-6 ACx 604-0120-3/0140-5/0120-6 ACx 604-0140-3/0170-5/0140-6 ACx 604-0170-3/0210-5/0170-6 ACx 604-0210-3/0260-5/0210-6 ACx 604-0260-6 ACx 604-0260-3/0320-5/0320-6 ACx 604-0320-3/0400-5/0400-6 1)

1x185 3) 1x120 3) 1x185
3)

22 30 22 44 44 44 44 44 44 55 55 55 30 30 30 30 30 30 30 30

1x(12-185) 1x(12-185) 1x(12-185) 2x(12-185) 2x(12-185) 2x(12-185) 2x(12-185) 2x(12-185) 2x(12-185) 4x(12-185) 4x(12-185) 4x(12-185) 1x(10-120) 1x(10-120) 3x(12-240) 3x(12-240) 3x(12-240) 3x(12-240) 3x(12-240) 3x(12-240)

1x(12-185) 1x(12-185) 1x(12-185) 2x(12-240) 2x(12-240) 2x(12-240) 2x(12-240) 2x(12-240) 2x(12-240) 4x(12-240) 4x(12-240) 4x(12-240)
1) 1)

30 30 30 44 44 44 44 44 44 55 55 55 30 30 44 44 44 44 44 44

M12 M12 M12 M12 M12 M12 M12 M12 M12 M10 (2x2 pcs) M10 (2x2 pcs) M10 (2x2 pcs) 41 mm2 2) 3) 41 mm2 2) 3) M10 (2 pcs)2)

30 30 30 30 30 30 30 30 30 35 35 35 30 30 30 30 30 30 30 30

(R7)

2x(12-185) 2x(12-185) 2x(12-185) 2x(12-185) 2x(12-185) 2x(12-185) 4x(12-185) 4x(12-185) 4x(12-185) 1x(10-120) 4) 1x(10-120) 4) 1x(10-240) 4)

2x(12-240) 2x(12-240) 2x(12-240) 2x(12-240) 2x(12-240) 2x(12-240) 4x(12-240) 4x(12-240) 4x(12-240)
1) 1)

(R8)

(R9)

(2xR8) (2xR9)

(R7)

1x(10-240) 4)

3x(12-240) 3x(12-240) 3x(12-240) 3x(12-240) 3x(12-240) 3x(12-240)

(R8)

1x(10-240) 4) 1x(10-240) 4) 1x(10-240) 4) 1x(10-240) 4)

M10 (2 pcs)2) M10 (2 pcs)2)

1x(10-240) 4) 1x(10-240) 4) 1x(10-240) 4) 1x(10-240) 4)

M10 (2 pcs)2) M10 (2 pcs)2)

(R9)

1x(10-240) 4) 1x(10-240) 4)

M10 (2 pcs)2)

2) 3) 4)

The maximum acceptable size of the cable is 3x120+70 (3x(AWG 0000) + AWG 00); crosssectional areas of copper conductors in mm2, 3 x phase conductor + PE conductor). Aluminium cable cannot be connected due to cable lug size. This is the earthing terminal for the PE bus and the frame of the ACx 604 module. The terminal is to be connected to the PE bus of the cabinet the module is installed in. Cable size: 6 AWG...300 MCM Isolated Stud terminal

A-8

ACS/ACC/ACP 604/6x7 Frequency Converters

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

External Control Connection Diagrams

External control connections of ACS 600 equipped with Standard Application Program (Factory Macro) are shown below. External control connections are different with other application macros and programs (see Firmware Manual). External control wiring is connected either directly to terminals on the NIOC board or through an optional terminal block. If an optional I/O terminal block is furnished, the control panel code (16th digit) of the ACS 600 type code is 4 or 5. Refer to Chapter 1 – Introduction for the ACS 600 type code description. An optional terminal block can be designated X2 (IEC standard designation) or 2TB (ANSI standard designation, for US manufactured units only). The 2TB arrangement is supplied in drives with 8 as the 20th digit of the ACS 600 type code. When making the external control connections compare carefully the terminal configuration found in the drive with diagrams below to ensure that the correct diagram is used. External control wiring of ACP 600 is connected either to terminals on the NIOC board or the NIOCP board. External control connections to NIOCP board are shown below.

ACS/ACC/ACP 604/6x7 Frequency Converters

A-9

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

NIOC Board

External control connections of NIOC board for ACS 600 with Standard Application Software (Factory Macro) are shown below. (For the connections of other application macros and programs see Firmware Manual).

ACS 601/604/607 NIOC Board (A2)

Programmable I/O Factory Settings

Terminal Block Size X21, X22: cables 0.5 to 1.5 mm2 (#20 to #16 AWG) X23, X25, X26, X27: cables 0.5 to 2.5 mm2 (#20 to #14 AWG) Control Cable Lead-through Size: ?: 2 x 3x2...11 mm

X21

1 2 3 4 5 6 7 8

VREF GND AI1+ AI1AI2+ AI2AI3+ AI3AO1+ AO1AO2+ AO2DI1 DI2 DI3 DI4 DI5 DI6 +24V +24V DGND +24 V GND RO11 RO12 RO13 RO21 RO22 RO23 R031 R032 R033

Reference voltage 10 V d.c.
1 k9< RL < 10 k9

Speed reference 0(2) ... 10 V
Rin > 200 k9

By default, not in use.
0(4) ... 20 mA, Rin = 100 9

By default, not in use.
0(4) ... 20 mA, Rin = 100 9

Factory settings of application software selection B (type code): DI1: Start, DI2: Stop, DI3: Reverse, DI4: Acc/Dec 2, DI5,6: Constant speed 1 to 3 select.

rpm

9 10 11 12
X22

Motor speed 0(4)...20 mA = 0...motor nom. speed, RL < 700 9 Output current 0(4)...20 mA =
0...motor nom. current, RL < 700 9

A

1
1)

Stop/Start Forward/Reverse 1) Not used ACCEL/DECEL 1/2 Constant speed select 2) Constant speed select 2) +24 V d.c. max. 100 mA Digital Ground Auxiliary voltage output, non-isolated, 24 V d.c. 250 mA

If Par. 10.3 is REQUEST. Operation: 0 = Open, 1 = Closed DI 5 0 1 0 1 DI 6 0 0 1 1 Output Set speed through AI1 Constant Speed 1 Constant Speed 2 Constant Speed 3

2 3 4 5 6 7 8 9
X23

2)

Connector X28 for RS 485 connection* 1 2 3 4 5 6 TRANS GND BA+ GND +24 V Standard Modbus Link

1 2
X25

1 2 3
X26

Relay output 1 Ready

Connector X29 for RS 485 connection*

1
1 2 3 4 5 6 TRANS FAULT BA+ GND +24 V * Connector shield is connected via RC filter to frame. Standard Modbus Link

2 3
X27

Relay output 2 Running

1 Fault 2 3

Relay output 3 Fault (-1)

A-10

ACS/ACC/ACP 604/6x7 Frequency Converters

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

Optional Terminal Block X2

External connections to optional terminal block X2 for ACS 600 Standard Application Program (Factory Macro) are shown below. (For the connections of other application macros and programs see Firmware Manual).

ACS 607 I/O Interface (optional)

ACS 601/604/607 NIOC Board (A2)

Terminal Block Size X21, X22: cables 0.5 to 1.5 mm2 (#20 to #16 AWG) X2, X23, X25, X26, X27: cables 0.5 to 2.5 mm2 (#20 to #14 AWG) Control Cable Lead-through Size: ?: 2 x 3x2...11 mm (0.08 to 0.43”)

Programmable I/O Factory Settings

X2

X21 ------------------------------------------------------------------------------------1 2 3 4 5 6 7 8 9 10 11 12 X22 VREF GND AI1+ AI1AI2+ AI2AI3+ AI3AO1+ AO1AO2+ AO2Reference voltage 10 V d.c.
1 k9< RL < 10 k9

Factory settings of application software selection B (type code): DI1: Start, DI2: Stop, DI3: Reverse, DI4: Acc/Dec 2, DI5,6: Constant speed 1 to 3 select.
1) 2)

1 2 3 4 5 6 7 8
rpm

Speed reference 0(2) ... 10 V Rin > 200 k9 By default, not in use. 0(4) ... 20 mA, Rin = 100 9 By default, not in use. 0(4)... 20 mA, Rin = 100 9 Motor speed 0(4)...20 mA = 0...motor nom. speed, RL < 700 9 Output current 0(4)...20 mA = 0...motor nom. current, RL < 700 9

Parameter 10.3 must be set to REQUEST. Operation: 0 = Open, 1 = Closed DI 5 0 1 0 1 DI 6 0 0 1 1 Output Set speed through AI 1 Constant Speed 1 Constant Speed 2 Constant Speed 3
A

9 10 11 12

Connector X28 for RS 485 connection* 1 2 3 4 5 6 TRANS GND BA+ GND +24V Standard Modbus Link

13 14 15 16 17 18 19 20 21 22

---------------------------------------------------------------------------------------------------------------------------------------------

1 2 3 4 5 6 7 8 9 X23 1 2 X25 1 2 3 X26 1 2 3 X27 1 2 3

DI1 DI2 DI3 DI4 DI5 DI6 +24V +24V DGND +24 V GND RO11 RO12 RO13 RO21 RO22 RO23 RO31 RO32 RO33

Stop/Start Forward/Reverse 1) Not used ACCEL/DECEL 1/2 Constant speed select 2) Constant speed select 2) +24 V d.c. max. 100 mA Digital Ground Auxiliary voltage output, nonisolated, 24 V d.c. 250 mA

Connector X29 for RS 485 connection* 1 2 3 4 5 6 TRANS FAULT BA+ GND +24V Standard Modbus Link

23 24 25 26 27 28 29 30 Fault 31 32

Relay output 1 Ready

* Connector shield is connected via RC filter to frame.

Relay output 2 Running

Relay output 3 Fault (-1)

ACS/ACC/ACP 604/6x7 Frequency Converters

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Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

Optional Terminal Block 2TB (US Version)

External connections to optional terminal block 2TB. This option is available only with ACS 600 Standard Application Program US version. External control connections with Factory Macro are shown below. (For the connections of other application macros and programs see Firmware Manual).
ACS 607 I/O Interface (optional)

ACS 601/604/607 NIOC Board (A2)

Terminal Block Size X21, X22: cables 0.5 to 1.5 mm2 (#20 to #16 AWG) 2TB, X23, X25, X26, X27: cables 0.5 to 2.5 mm2 (#20 to #14 AWG) Control Cable Lead-through Size: ?: 2 x 3x2...11 mm (0.08 to 0.43”)

Programmable I/O Factory Settings

2TB

X21 ------------------------------------------------------------------------------------1 2 3 4 5 6 7 8 9 10 11 12 X22 ------------------------------------------1 2 3 4 5 6 7 8 9 X23 -----------------------------------------------------------------------------1 2 X25 1 2 3 X26 1 2 3 X27 1 2 3 RO11 RO12 RO13 RO21 RO22 RO23 RO31 RO32 RO33 Relay output 1 Ready +24 V GND Auxiliary voltage output, nonisolated, 24 V d.c. 250 mA DI1 DI2 DI3 DI4 DI5 DI6 +24V +24V DGND Digital Ground Start Stop Forward/Reverse 1) ACCEL/DECEL 1/2 Constant speed select 2) Constant speed select 2) +24 V d.c. max. 100 mA VREF GND AI1+ AI1AI2+ AI2AI3+ AI3AO1+ AO1AO2+ AO2Reference voltage 10 V d.c.
1 k9< RL < 10 k9

Factory settings of application software selection B (type code): DI1: Start, DI2: Stop, DI3: Reverse, DI4: Acc/Dec 2, DI5,6: Constant speed 1 to 3 select.
1) 2)

1 2 3 4 5 6 7 8
rpm

Speed reference 0(2) ... 10 V Rin > 200 k9 By default, not in use. 0(4) ... 20 mA, Rin = 100 9 By default, not in use. 0(4) ... 20 mA, Rin = 100 9 Motor speed 0(4)...20 mA = 0...motor nom. speed, RL < 700 9 Output current 0(4)...20 mA = 0...motor nom. current, RL < 700 9

Parameter 10.3 must be set to REQUEST. Operation: 0 = Open, 1 = Closed DI 5 0 1 0 1 DI 6 0 0 1 1 Output Set speed through AI 1 Constant Speed 1 Constant Speed 2 Constant Speed 3
A

9 10 11 12 13 14 15 16 17

Connector X28 for RS 485 connection* 1 2 3 4 5 6 TRANS GND BA+ GND +24V Standard Modbus Link

18 19 20 21 22 23 24 25

Connector X29 for RS 485 connection* 1 2 3 4 5 6 TRANS FAULT BA+ GND +24V Standard Modbus Link

26 27 28 29 30 31 32 33 34 Fault 35 36

* Connector shield is connected via RC filter to frame.

Relay output 2 Running

Relay output 3 Fault (-1)

A-12

ACS/ACC/ACP 604/6x7 Frequency Converters

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

NIOCP Board

External control connections of ACP 600 with NIOCP board (and Speed Control Application Macro) are shown below. (For the connections of other application macros and programs see Firmware Manual).

Terminal Block Size X1, X2, X4, X5, X8: cables 0.5 to 1.5 mm2 X7: cables 0.5 to 2.5 mm2 Control Cable Lead-through Size: ?: 2 x 3x2...11 mm

rpm

Connector X300 for RS 485 connection* 1 2 3 4 5 6 TRANS GND BA+ GND +24 V * Connector shield is connected via RC filter to frame. Standard Modbus Link

Terminal Block X1 1 +10 V 2 AGND 3 –10 V 4 AI1+ 5 AI1– 6 AI2+ 7 AI2– 8 AO1+ 9 AO1– Terminal Block X2 1 DI1 2 DI2 3 DI3 4 DI4 5 DI5 6 DI6 7 DI7 8 DI8 9 DI9 10 DI10 11 DI11 12 DI12 13 +24 DV 14 +24 DV 15 +24 DV 16 DGND Terminal Block X4 1 +24 V 2 DGND Terminal Block X5 1 +24 DV 2 DO1 3 DO2 4 DO3 5 DO4 6 DGND Terminal Block X8 1 UENC+ 2 SENSE+ 3 SENSE– 4 UENC– 5 A+ 6 A– 7 B+ 8 B– 9 Z+ 10 Z– Terminal Block X7 1 RO1 NCC 2 RO1 CM 3 RO1 NOC

Function Reference Voltage +10 VDC Analogue Ground Reference Voltage –10 VDC External Reference 1: Speed Reference External Reference 2: Not defined SPEED ACT 1

START/STOP Not defined FAULT RESET SPEED REF SW2 ACC/DEC 1/2 SEL

Not defined

Control Voltage Output +24 V d.c. max. 135 mA Digital Ground Auxiliary Voltage Output 0V Control Voltage Input ACT SPEED=0 RUNNING FAULT (-1) ACT SPEED=REF Digital Ground Power Supply Sense+ Sense– 0V Channel A+ Channel A– Channel B+ Channel B– Channel Z+ Channel Z–

1 Relay Output, READY Signal

ACS/ACC/ACP 604/6x7 Frequency Converters

A-13

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

NIOC Board Chaining

When several NIOC boards are daisy-chained for common control from an external Modbus device the bus termination switch (SW1) must be set on the participating boards as shown below.

NIOC No 1

SW1 ON

NIOC No 2

SW1 OFF

NIOC No 3

SW1 OFF

NIOC No 4

SW1 ON

X28

X29
Drive units at a common earth potential (e.g. installed in the same cabinet) Note: When drive units are not at a common earth potential, or long distance connection is required, NBCI modules can be used. Refer to the module manual.

This board should have SW1 in the OFF position if the external Modbus device has a bus termination circuit. If in doubt, set SW1 to ON here.

RS 485 Modbus

Straight-through cable (Ident.: Grey) (pin 1 to pin 1, pin 2 to pin 2, etc.)

Settings of Switch SW1

Function

NAMC off
... ...

OFF on OFF ON

Termination OFF

NIOC

Termination ON (default)

A-14

ACS/ACC/ACP 604/6x7 Frequency Converters

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

NIOC and NIOCP Board Specifications

Data of the external control connection boards of the ACS 600 product family are given below.

ACS/ACC/ACP 600 NIOC-01 Board Analogue Inputs The advantage of the differential analogue input is that the earth potential of the device or transmitter sending an analogue signal can differ up to ± 15 V from the earth potential of the ACx 600 chassis without disturbing the signal. Differential input also efficiently attenuates common mode disturbances coupled to control cables. ACS 600: Two Programmable Differential Current Inputs: 0 (4) to 20 mA, Rin = 100 W ACC 600: Two Differential Current Inputs: 0 to 20 mA, Rin = 100 W ACP 600: One Programmable Differential Current Input: 0 to 20 mA, Rin = 100 W ACS/ACP 600: One Programmable Differential Voltage Input: ACS 600: 0 (2) to 10 V, Rin > 200 kW; ACP 600: 0 to 10 V, Rin > 200 kW ACC 600: One Differential Voltage Input: 0 to 10 V, Rin > 200 kW Common Mode Voltage: ± 15 VDC, max. Common Mode Rejection Ratio: > 60 dB at 50 Hz Resolution: 0.1 % (10 bit) Inaccuracy: ± 0.5 % (Full Scale Range) at 25 °C. Temperature Coefficient: ± 100 ppm/°C, max. Input Updating Time:
Application Program Standard 5.x Standard 6.x Crane 12 ms AI1: 12 ms, AI2 and AI3: 6 ms * 44 ms Updating Time

ACP 600 NIOCP-01 Board Two Bipolar Differential Voltage Inputs:

± 10 V, Rin = 30 kW
Common Mode Voltage: ± 20 VDC, max. Common Mode Rejection Ratio: > 60 dB at 50 Hz Resolution: 0.02 % (12 bit) Accuracy: 11 bit Inaccuracy: ± 0.1 % (Full Scale Range) at 25 °C. Temperature Coefficient: ± 100 ppm/°C, max. Input Updating Time: 1 ms

Motion Control 1 ms * 12 ms with NAIO extension module

Constant Voltage Output

Voltage: 10 VDC ± 0.5 % (Full Scale Range) at 25 °C. Temperature Coefficient: ± 100 ppm/ °C, max. Maximum Load: 10 mA Applicable Potentiometer: 1 kW to 10 kW

Voltage: ± 10 VDC ± 0.5 % (Full Scale Range) at 25 °C. Temperature Coefficient: ± 100 ppm/°C, max. Maximum Load: 10 mA Applicable Potentiometer: > 1 kW Voltage: 24 VDC ± 10 %, Short circuit proof Maximum Current: 300 mA

Auxiliary Power Output

Voltage: 24 VDC ± 10 %, Short circuit proof Maximum Current: 250 mA (130 mA with NLMD-01 option)

ACS/ACC/ACP 604/6x7 Frequency Converters

A-15

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

ACS/ACC/ACP 600 NIOC-01 Board Analogue Outputs ACS/ACC 600: Two Programmable Current Outputs: 0 (4) to 20 mA, RL < 700 W ACP 600: One Programmable Current Output: 0 to 20 mA, RL < 700 W Resolution: 0.1 % (10 bit) Inaccuracy: ± 1 % (Full Scale Range) at 25 °C. Temperature Coefficient: ± 200 ppm/°C, max. Output Updating Time:
Application Program Standard 5.x Standard 6.x Crane Motion Control Updating Time 24 or 100 ms 24 ms 44 ms 8 ms

ACP 600 NIOCP-01 Board One Bipolar Programmable Voltage Output: + 10 V, RL > 2 kW Resolution: 0.02 % (12 bit) Accuracy: 10 bit Inaccuracy: ± 0.1 % (Full Scale Range) at 25 °C. Temperature Coefficient: ± 200 ppm/°C, max. Output Updating Time: 2 ms Output Rising Time: 3 ms

Digital Inputs

ACS/ACP 600: Six Programmable Digital Inputs (Common Ground): 24 VDC, -15 % to +20 % ACC 600: Six Digital Inputs (Common Ground): 24 VDC, -15 % to +20 % Logical Thresholds: < 8 VDC > 12 VDC “1” “0”,

12 Programmable Digital Inputs (Common Ground): 24 VDC, -15 % to +20 % Logical Thresholds: < 8 VDC > 12 VDC “1” Filtering Time Constant: ? 50 ms DI 11 and DI 12 can be used for time measurement between two external events (PROBE1 and PROBE2). Internal Supply For Digital Inputs (+24 VDC): Short circuit proof, group isolated Isolation Test Voltage: 500 VAC, 1 minute Input Updating Time: 1 ms An external 24 VDC supply can be used instead of the internal supply. Filtering Time Constant: ? 100 ms “0”,

Input Current: DI1 to DI 5: 10 mA, DI6: 5 mA Filtering Time Constant: 1 ms Thermistor Input: 5 mA, < 1.5 kW “1” (normal temperature), > 4 kW “0” (high temperature), Open Circuit “0” (high temperature) Internal Supply For Digital Inputs (+24 VDC): Short circuit proof, group isolated Isolation Test Voltage: 500 VAC, 1 minute Input Updating Time:
Application Program Standard 5.x Standard 6.x Crane Motion Control 12 ms 6 ms 44 ms 4 ms Updating Time

An external 24 VDC supply can be used instead of the internal supply. Digital Outputs

-

Four Programmable Digital Outputs: Short circuit proof, Overload protection Maximum Load: 10 mA with internal 24 V supply, 100 mA with external supply Output Updating Time: 2 ms

A-16

ACS/ACC/ACP 604/6x7 Frequency Converters

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

ACS/ACC/ACP 600 NIOC-01 Board Relay Outputs Three Programmable Relay Outputs Switching Capacity: 8 A at 24 VDC or 250 VAC, 0.4 A at 120 VDC Minimum Continuous Current: 5 mA rms at 24 VDC Maximum Continuous Current: 2 A rms Contact Material: Silver Cadmium Oxide (AgCdO) Isolation Test Voltage: 4 kVAC, 1 minute Output Updating Time: 100 ms (ACS 600), 44 ms (ACC 600), 8 ms (ACP 600) DDCS Fibre Optic Link Modbus Communication Link

ACP 600 NIOCP-01 Board One Relay Output Switching Capacity: 8 A at 24 VDC or 250 VAC, 0.4 A at 120 VDC Minimum Continuous Current: 5 mA rms at 24 VDC Max Continuous Current: 2 A rms Contact Material: Silver Cadmium Oxide (AgCdO) Isolation Test Voltage: 4 kVAC, 1 minute Output Updating Time: 2 ms

Protocol: DDCS (ABB Distributed Drives Communication System) RS 485 Transmission Rate: Max. 9600 bit/s Parity: Selectable Connectors: Shielded modular telecommunication socket

Encoder Input

One Encoder Input: 3 channel differential, frequency ? 200 kHz, supply cable resistance compensation. COMBICON connector, 10 pins. Meets the EIA standard RS 422. Encoder supply: +5 VDC ... +10 VDC, short circuit proof, max. 150 mA. Required Encoder Type: the type listed here or equivalent: · GI 356 (IRION & VOSSELER) · ROD 426A (Heidenhain) Encoder Signals: Signal level/Load capacity: 5 V rectangular-pulse signals; Time between edges: a > 0,8 ms at fmax ; Edge steepness: tv ? 120 ns; Delay of reference signal Z (zero pulse): td ? 60 ns; Sampling frequency: fmax = 200 kHz.

ACS/ACC/ACP 604/6x7 Frequency Converters

A-17

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

Encoder Signals

A characteristic of encoder signals in applications using the incremental encoder for forward direction is presented below.
tv a a a a tv

5V A+ 5V B+
td

5V Z+
a a a a td tv tv

5V A5V Btd

5V Ztd

A-18

ACS/ACC/ACP 604/6x7 Frequency Converters

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

Enclosures, Space Requirements
ACx 600 Type

The cabinets, degrees of protection and free space requirements of ACx 600 types are given below.
Enclosure Degree of Protection
5)

Space above Space below

Space on left/right mm 50/50 50/50
4)

Space in front/back mm 20/0 20/0 100/0 200/0 in 0.8/0 0.8/0 4/0 8/0

mm 601 604 604 6x7
1) 2) 2) 3)

in 12 12 16 8

mm 300 300 0 0

in 12 12 0 0

in 2/2 2/2

wall-mounted metal frame frame R7 frames R8 and R9 Common cabinet

IP 22/IP 54 IP 22 IP 00 IP 21 /22 IP 42/54
5)

1)

300 300 400 200

50 /50 2/2 0 0

not for R7 frame size (ACx 601-0100-3, -0120-3, -0120-5, -0140-5, -0100-6, -0120-6), not for ACP 601 units ACx 604-0100-3, -0120-3, -0120-5, -0140-5, -0100-6, -0120-6 3) ACx 604-0140-3 to -0320-3 & -0170-5 to -0400-5, -0140-6 to -0400-6 4) 50 mm is needed for air-cooling. In addition, free space is needed for terminal connections. 5) louvred gratings which are visible on the dimensional drawings are not included 6) The degrees of protection is specified by listing the IEC standard IP (Ingress Protection) number. The first digit of the IP number specifies the protection against solid objects and dirt. The second digit specifies the protection against liquids. IP 00 is an open chassis. NEMA 1 enclosures are comparable to approximately IP 20 to IP 33. NEMA 3R enclosures are comparable to IP 32. NEMA 12 and NEMA 13 enclosures are comparable to IP 54 to IP 65. NEMA 4 enclosures are comparable to IP 65 or IP 66. 0 1 2 3 4 Second digit of IP number (protection against liquids) Not protected Protected against dripping water Protected against downward sprays of water up to 15 degrees from vertical. Protected against solid objects larger than 2.5 mm (0.1 in.) dia. Protected against downward sprays of water up to 60 degrees from vertical. Protected against solid objects larger than 1.0 mm (0.04 in.) dia. Protected against light sprays or splashing water from all directions - water shall not enter the enclosure in harmful quantities. Dust protected - dust shall not enter the enclosure in sufficient Protected against low pressure sprays of water from all directions quantity to interfere with satisfactory operation of equipment. - water shall not enter the enclosure in harmful quantities. Dust tight Protected against heavy seas on shipdecks or strong sprays of water from all directions - water shall not enter the enclosure in harmful quantities. First digit of IP number (protection against solid objects) Not protected Protected against solid objects larger than 50 mm (2 in.) dia. Protected against solid objects larger than 12 mm (1/2 in.) dia.

5 6

Space requirement for the door opening 700 mm (27.6 in.) (2 x R8 and 2 x R9) 800 mm (31.5 in.) (R7, R8 and R9)

ACS/ACC/ACP 604/6x7 Frequency Converters

A-19

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

Cooling Air Flow Requirements

Cooling air flow requirements are given below.
ACx 60x 60x = 604/6x7 ACx 60x-0100-3/0120-5/0100-6 ACx 60x-0120-3/0140-5/0120-6 ACx 60x-0140-3/0170-5/0140-6/0170-6 ACx 60x-0170-3/0210-5/0210-6 ACx 60x-0210-3/0260-5/0260-6 ACx 60x-0260-3/0320-5/0320-6 ACx 60x-0320-3/0400-5/0400-6 ACx 6x7-0400-3/0490-5/0490-6 ACx 6x7-0490-3/0610-5/0610-6 ACx 6x7-0610-3/0760-5/0760-6 Flow m3/h 660 660 1640 1640 1640 1840 1840 3580 3980 3980

Heat Losses and Noise Levels

Heat losses and noise levels are given below.
Frequency Converter Type ACx 604/607-0100-3 ACx 604/607-0120-3 ACx 604/607-0140-3 ACx 604/607-0170-3 ACx 604/607-0210-3 ACx 604/607-0260-3 ACx 604/607-0320-3 ACx 6x4/6x7-0400-3 ACx 6x4/6x7-0490-3 ACx 6x4/6x7-0610-3 ACx 604/607-0120-5 ACx 604/607-0140-5 ACx 604/607-0170-5 ACx 604/607-0210-5 ACx 604/607-0260-5 ACx 604/607-0320-5 ACx 604/607-0400-5 ACx 6x4/6x7-0490-5 ACx 6x4/6x7-0610-5 ACx 6x4/6x7-0760-5 ACx 604/607-0100-6 ACx 604/607-0120-6 ACx 604/607-0140-6 ACx 604/607-0170-6 ACx 604/607-0210-6 ACx 604/607-0260-6 ACx 604/607-0320-6 ACx 604/607-0400-6 ACx 6x4/6x7-0490-6 ACx 6x4/6x7-0610-6 ACx 6x4/6x7-0760-6 Heat Loss kW 1.9 2.3 2.8 3.3 4.0 5.0 6.3 7.9 10.0 12.5 2.3 2.8 3.3 4.0 5.0 6.3 7.9 10.0 12.5 15.8 1.9 2.3 2.8 3.3 4.0 5.0 6.3 7.9 10.0 12.5 15.8 Noise dB (A) 65.8 65.8 61.8 61.8 61.8 67.6 67.6 65 71 71 65.8 65.8 61.8 61.8 61.8 67.6 67.6 65 71 71 65.8 65.8 61.8 61.8 61.8 61.8 67.6 67.6 65.0 71.0 71.0

A-20

ACS/ACC/ACP 604/6x7 Frequency Converters

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

Dimensions and Weights (ACx 604)
ACS 6 00

Dimensions and weights of the ACx 604s are given below.

ACS 604 Type
U2

Height mm (in) 860 (33.86) 860 (33.86) 1250 (49.2) 1250 (49.2) 1250 (49.2) 1600 (63) 1600 (63)

Width mm (in) 480 (18.89) 480 (18.89) 462*/524 (18.19/20.63) 462*/524 (18.19/20.63) 462*/524 (18.19/20.63) 462*/524 (18.19/20.63) 462*/524 (18.19/20.63) 462*/524 (18.19/20.63) 462*/524 (18.19/20.63)

Depth mm (in) 428 (16.85) 428 (16.85) 407 (16) 407 (16) 407 (16) 407 (16) 407 (16) 407 (16) 407 (16)

Weight kg (lbs) 88 (194) 88 (194) 135 (297) 140 (308) 140 (308) 166 (365) 166 (365) 171 (376) 171 (376)

0100-3 0120-3 0140-3

0120-5 0100-6 0140-5 0120-6 0170-5 0140-6/ 0170-6 0210-5 0210-6 0260-5 0260-6

V2

0170-3
W2 UD C + UD C -

0210-3 0260-3 0320-3

PE

0320-5 0320-6 0400-5 0400-6 0400-3 0490-3 0610-3 0490-5 0490-6 0610-5 0610-6 0760-5 0760-6

1600 (63) 1600 (63)

2 x Dimensions of ACx 604-0210-3 2 x Dimensions of ACx 604-0260-3 2 x Dimensions of ACx 604-0320-3

Width marked with * does not include motor cable terminals, PE terminal or DC bus terminals.

ACS/ACC/ACP 604/6x7 Frequency Converters

A-21

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

Dimensions and Weights (ACx 6x7)

Dimensions and weights of the ACx 6x7s are given below.

ACx 6x7 Type 0100-3 0120-5 0100-6 0120-3 0140-5 0120-6 0140-3 0170-5 0140-6/0170-6 0170-3 0210-5 0210-6 0210-3 0260-5 0260-6 0260-3 0320-3 0320-5 0320-6 0400-5 0400-6 0400-3 0490-5 0490-6 0490-3 0610-5 0610-6 0610-3 0760-5 0760-6

Height 1) mm (in) 20781)/23162) (81.8)/(91.2) 20781)/23162) (81.8)/(91.2) 20781)/23162) (81.8)/(91.2) 20781)/23162) (81.8)/(91.2) 20781)/23162) (81.8)/(91.2) 20781)/23162) (81.8)/(91.2) 20781)/23162) (81.8)/(91.2) 20781)/23162) (81.8)/(91.2) 20781)/23162) (81.8)/(91.2) 20781)/22152) (87.3)/(87.2) 20781)/2215)2) (87.3)/(87.2) 20781)/22152) (87.3)/(87.2)

Width mm (in) 830 (32.7) 830 (32.7) 830/12303) (32.7)/(48.4) 830/12303) (32.7)/(48.4) 830/12303) (32.7)/(48.4) 830/12303) (32.7)/(48.4) 830/12303) (32.7)/(48.4) 830/12303) (32.7)/(48.4) 830/12303) (32.7)/(48.4) 21306) (83.9) 21306) (83.9) 21306) (83.9)

Depth mm (in) 644 (25.35) 644 (25.35) 644 (25.35) 644 (25.35) 644 (25.35) 644 (25.35) 644 (25.35) 644 (25.35) 644 (25.35) 644 (25.35) 644 (25.35) 644 (25.35)

Weight 4) kg (lbs) 275/3005) (605)/(660) 275/3005) (605)/(660) 340/3905) (748)/(858) 345/3905) (749)/(858) 345/3905) (749)/(858) 370 (814) 370 (814) 375/4355) (825)/(957) 375/4355) (825)/(957) 710 (1562) 870 (1914) 870 (1914)

1)

2) 3)

Height of bottom entry/exit, degree of protection IP 21 / IP 22 / IP 42. Heights include the lifting lugs. Height of top entry/exit is 2132 (83.9 in). Degree of protection IP 54 EMC Line Filter version

4) 5) 6)

Weight of the IP 21 / IP 22 / IP 42 version Weight of the 690 V unit with du/dt filter With cable top exit an additional 400 mm wide section

A-22

ACS/ACC/ACP 604/6x7 Frequency Converters

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

Braking Chopper Dimensions
Width with Braking Chopper

The widths of units with braking chopper are below.

ACx 6x7 Type

Width with Braking Chopper and Resistor(s) mm (in) 1230 (48.4) 1230 (48.4) 1230 (48.4) 1530 (60.2) 1530 (60.2) 1530 (60.2) 1530 (60.2) 3530 (139) 3530 (139) 3530 (139)

ACx 6x7 Type

Width with Braking Chopper

Width with Braking Chopper and Resistor(s) mm (in) 1230 (48.4) 1230 (48.4) 1230 (48.4) 1230 (48.4) 1530 (60.2) 1530 (60.2) 1530 (60.2) 3530 (139) 3530 (139) 3530 (139)

ACx 6x7 Type

Width with Braking Chopper

Width with Braking Chopper and Resistor(s) mm (in) 1230 (48.4) 1230 (48.4) 1230 (48.4) 1230 (48.4) 1230 (48.4) 1530 (60.2) 1530 (60.2) 1530 (60.2) 3530 (139) 3530 (139) 3530 (139)

mm (in) 0100-3 0120-3 0140-3 0170-3 0210-3 0260-3 0320-3 0400-3 0490-3 0610-3 830 (32.7) 830 (32.7) 1230 (48.4) 1230 (48.4) 1230 (48.4) 1230 (48.4) 1230 (48.4) 2930 (115.4) 2930 (115.4) 2930 (115.4)

mm (in) 0120-5 0140-5 0170-5 0210-5 0260-5 0320-5 0400-5 0490-5 0610-5 0760-5 830 (32.7) 830 (32.7) 1230 (48.4) 1230 (48.4) 1230 (48.4) 1230 (48.4) 1230 (48.4) 2930 (115.4) 2930 (115.4) 2930 (115.4)

mm (in) 0100-6 0120-6 0140-6 0170-6 0210-6 0260-6 0320-6 0400-6 0490-6 0610-6 0760-6 830 (32.7) 830 (32.7) 1230 (48.4) 1230 (48.4) 1230 (48.4) 1230 (48.4) 1230 (48.4) 1230 (48.4) 2930 (115.4) 2930 (115.4) 2930 (115.4)

ACS/ACC/ACP 604/6x7 Frequency Converters

A-23

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

Application Programs

Various application programs are available for the ACS 600 frequency converters. Not all selections are available for all types. One application program at a time can be loaded in the memory of the frequency converter.
ACS 600 Application Programs Standard Pump and Fan Control (PFC) Master/Follower (M/F) Spinning Control Motion Control Crane System Decanter Centrifuge Extruder Centrifuge

Application Macros

The macros of the application programs are introduced below.
Application Program Standard Macros Factory Hand/Auto PID Control Torque Control Sequential Control User macro 1 & 2 Pump and Fan Control Pump and Fan Control Hand/Auto For... basic industrial applications applications that require frequent switching between two external control locations closed loop processes processes that require torque control operation at preset constant speeds user’s own customised parameter settings pump or fan station control applications that require frequent switching between two external control locations and/or speed control of a pump or a fan drives which are coupled to each other

Master/ Follower

Master/Follower + macros included in Standard Application program Spinning control Torque Control Speed Control Positioning Synchronising User macro 1 & 2

Spinning Control Motion Conrol

running motor rotating bobbins in ring-frame machines processes that require torque control closed loop speed control point-to-point positioning positioning to moving target user’s own customised parameter settings normal crane drive two crane drive applications with Master/Follower operation user’s own customised parameter settings separating solid particles from liquids extruder drives

Crane

Crane Master/Follower Control User macro 1 & 2

Decanter Centrifuge Extruder

Decanter Extruder, Hand/Auto, PID Control, Torque Control, Sequential Control, User macro 1&2 Centrifuge Traverse

Centrifuge Traverse Control

centrifuge drives textile machines

A-24

ACS/ACC/ACP 604/6x7 Frequency Converters

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

Macro/Language Combinations

Languages and application macros included in each ACx 600 application program are shown below. Not all selections are available for all types.
Type code character no. 15 B*, ** C** D E Application Macros Languages

Application Program

Standard

Factory, Hand/Auto, PID Control, Torque Control, Sequential Control Factory, Hand/Auto, PID Control, Torque Control, Sequential Control Factory, Hand/Auto, PID Control, Torque Control, Sequential Control Factory, Hand/Auto, PID Control, Torque Control, Sequential Control PFC (Pump and Fan Control) Pump and Fan Control, Hand/Auto Pump and Fan Control, Hand/Auto Master/Follower + Macros included in selection C Master/Follower + Macros included in selection D Master/Follower + Macros included in selection E Master/Follower + Macros included in selection B System application (ACS 600 MultiDrive) ACP 600: Torque Control, Speed Control, Positioning, Synchronising ACP 600: Torque Control, Speed Control Crane, Master/Follower Control Spinning control Application program template (FCB Programmable) Special application program Decanter Extruder, Hand/Auto, PID Control, Torque Control, Sequential Control, User macro 1 & 2 Centrifuge Traverse

English (UK & Am), French, Spanish, Portuguese English (UK & Am), German, Italian, Dutch English (UK & Am), Danish, Swedish, Finnish English (UK & Am), French, Spanish, Portuguese English (UK & Am), German, Italian, Dutch English (UK & Am), Danish, Swedish, Finnish English (UK & Am), French, Spanish, Portuguese English (UK & Am), German, Italian, Dutch English (UK & Am), Danish, Swedish, Finnish English (UK & Am), French, Spanish, Portuguese English (UK & Am), French, Spanish, Portuguese English, German English, German English, German English English English Custom specified English, German English, German

Pump and Fan Control

F** G H

Master/Follower

J ** K L M*, **

System Motion Control

N P Q

Crane Spinning Control Custom

S V T Y

Decanter Centrifuge Extruder

P Q

Centrifuge Traverse Control

2 1

English English

* This selection is for the North American market. The default parameter settings in the standard application macros include minor changes to fulfil the local regulations, such as 3-wire start/ stop. **Standard Application Program version 6.x includes MASTER/FOLLOWER Parameter Group and the following languages: Czech, Danish, Dutch, English (UK & Am), Finnish, French, German, Italian, Polish, Spanish, Swedish, Portuguese. **PFC Application Program version 6.x includes the following languages: Czech, Danish, Dutch, English (UK & Am), Finnish, French, German, Italian, Polish, Spanish, Swedish, Portuguese.

ACS/ACC/ACP 604/6x7 Frequency Converters

A-25

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

Protection Features

Application program dependent features of the ACx 600 are listed below. available as standard, optional. Not all selections are available for all types. For more information refer to the appropriate application program Firmware Manual.
Motion Control Motion Control MotionControl

Standard PFC, M/F

Standard PFC, M/F

System

System

ACx 600 temperature Overcurrent Short circuit DC overvoltage Supply phase DC undervoltage Overfrequency Loss of Control Panel Internal fault Internal fault on the I/O control board Ambient temperature User Macro Braking chopper (in fieldbus mode) Inverter overload No motor data ID Run fail Motor fan control and diagnostics

Analogue input below minimum value Loss of Control Panel External fault Motor overtemperature Thermistor/Pt 100 Motor stalled Motor underload Loss of motor phase Earth fault Speed measurement Motor overspeed Torque Torque proving Master/Follower communication Brake Communication test Following error Position limits Communication error Encoder interface module Overspeed

Speed Motor current Motor torque Motor speed Reference 1 Reference 2 Actual value 1 Position error Synchron error Position threshold Joystick Brake long falling time

2

2

2

4

Preprogrammed Warnings: ACS 600 temperature, Motor Identification Run, Drive Identification Number change, User Macro, Target position (ACP). Programmable Automatic Reset Functions (ACS 600 Standard Application Program only): after overcurrent, overvoltage, undervoltage and analogue input below minimum value. Information Functions: ACx 600 control firmware package version, ACx 600 application program version, ACx 600 test date.

A-26

ACS/ACC/ACP 604/6x7 Frequency Converters

System

Crane

Crane

Crane

Preprogrammed Faults

Programmable Fault Functions

Programm. Supervision Functions

Standard PFC, M/F

2

2

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

Applicable Standards

The ACS 600 complies with the following standards: ? EN 60204-1: 1992 + Corr. 1993 (IEC 204-1). Safety of machinery. Electrical equipment of machines. Part 1: General requirements. Provisions for compliance: The final assembler of the machine is responsible for installing - an emergency-stop device - a supply disconnecting device (ACx 601 and ACx 604) - the ACx 604 (IP 00) into a separate casing. ? EN 60529: 1991 (IEC 529), IEC 664-1: 1992. Degrees of protection provided by enclosures (IP code). ? EN 61800-3 (1996): EMC product standard including specific test methods. ? AS/NZS 2064 (1997): Limits and methods of measurement of electronic disturbance characteristics of industrial, scientific and medical radiofrequency equipment. (ACS 600 complies with the requirements given for class A equipment.) This standard is applied in Australia and New Zealand.

Materials
Enclosure (ACx 601) PS (polystyrene) 3 mm hot-dip zinc coated steel sheet 1.5 to 2 mm painted with epoxy polyester powder paint anodised aluminium profile (R2 to R6) Enclosure (ACx 604/6x7) hot-dip zinc coated steel sheet 1.5 to 2 mm with polyester thermosetting powder coating Package (ACx 604/6x7) wood or plywood (seaworthy package). Plastic covering of the package: PE-LD, bands PP or steel. 60 mm RAL 7035 Thickness of Coating 60 mm Color NCS 1502-Y (RAL 90021 / PMS 420 C) NCS 8502-Y (RAL 9004 / PMS 426 C) semigloss black ES 900

Transportation Position

ACx 604/6x7: Upright. Units without du/dt filters can be transported also on their back in their protective package.

ACS/ACC/ACP 604/6x7 Frequency Converters

A-27

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

Disposal

ACx 600 contains raw materials that should be recycled, thus preserving energy and natural resources. Package materials of ACx 600 units and options are environmentally compatible and recyclable. All metal parts can be recycled. The plastic parts can either be recycled or burned under controlled circumstances, according to local regulations. If recycling is not feasible, all parts excluding electrolytic capacitors can be landfilled. The DC capacitors of the unit contain electrolyte which is classified as hazardous waste. (Location of the electrolytic capacitors is shown on a sticker in the back of the front cover, C11 to C13.) The capacitors must be removed and handled according to local regulations. For further information on environmental aspects, please contact your local ABB distributor.

CE Marking

A CE mark is attached to ACx 601/607/627 frequency converters to verify that the unit follows the provisions of the European Low Voltage and EMC Directives (Directive 73/ 23/EEC, as amended by 93/68/EEC and Directive 89/336/EEC, as amended by 93/68/ EEC). EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to operate without problems within an electromagnetic environment. Likewise, the equipment must not disturb or interfere with any other product or system within its locality. The EMC Directive defines the requirements for immunity and emissions of electrical equipment used in the European Economic Area. The EMC product standard EN 61800-3 covers the requirements stated for frequency converters. The ACx 607/627 frequency converters (55 kW to 630 kW) comply with the EMC Directive in industrial low-voltage network, public low-voltage network (restricted distribution) and IT networks (unearthed mains) with the following provisions:

Compliance with the EMC Directive

Industrial Low-Voltage Network

1. It is ensured that no excessive emission is propagated to neighbouring lowvoltage networks. In some cases, the natural suppression in transformers and cables is sufficient. If in doubt, the ACx 600 can be equipped with EMC filtering (refer to Table A-1) or the supply transformer with static screening between the primary and secondary windings can be used. 2. The ACx 6x7 is installed according to the instructions given in this manual. 3. The motor and control cables are selected as specified in this manual. Note: It is recommended to equip the ACx 600 with the EMC filtering if there is equipment sensitive to conducted emission connected to the same supply transformer as the ACx 600.

A-28

ACS/ACC/ACP 604/6x7 Frequency Converters

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data
Table A-1 The EMC filtering of the ACx 600 units is marked in the type code as follows. * du/dt Filters + EMC Filters, ** du/dt Filters + No EMC Filters. Type Code ACS 600 Type ACS/ACC/ACP 604
Character no. ACxxxxxxxxxxxxxxxxxxxx EMC Filter Selections 0 No EMC Filter Selections 9

20

ACS/ACC/ACP 6x7 (55 to 630 kW)

ACxxxxxxxxxxxxxxxxxxxx

0, 3*

5**, 9

20

Medium voltage network Supply transformer Neighbouring network

Static screen

Point of measurement Low voltage Equipment (victim) Equipment Equipment Low voltage ACx 600

Use of the ACx 600 in Second Environment without EMC filtering (EN 61800-3: second environment includes all establishments other than those directly connected to a lowvoltage power supply network which supplies buildings used for domestic purposes.)

Public Low-Voltage Network

1. The ACx 600 is equipped with EMC filtering (refer to Table A-1). 2. The ACx 6x7 is installed according to the instructions given in this manual. 3. The motor and control cables are selected as specified in this manual. 4. Maximum cable length is 100 metres. Without considering the EMC requirements, do not use the ACx 600 on a low voltage public network supplying domestic premises. This kind of use might cause radio frequency interference.

Unearthed Mains (IT Network)

1. It is ensured that no excessive emission is propagated to neighbouring lowvoltage networks. In some cases, the natural suppression in transformers and cables is sufficient. If in doubt, the supply transformer with static screening between the primary and secondary windings can be used. 2. The ACx 6x7 is installed according to the instructions given in this manual. 3. The motor and control cables are selected as specified in this manual. Note: The ACx 600 must not be equipped with EMC filtering (refer to Table A-1) when installed to IT networks. The mains becomes connected to earth potential through the EMC filter capacitors. In IT networks this may cause danger or damage the unit.

ACS/ACC/ACP 604/6x7 Frequency Converters

A-29

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

Machinery Directive

ACx 601/604/607/627 frequency converters comply with the European Union Machinery Directive (98/37/EC) requirements for an equipment intended to be incorporated into machinery. The UL/CSA markings are often required in North America. The UL/ULC/CSA markings of the ACS 600 frequency converters are listed below (x). ACx 600 Type ACS 601 (IP 22) 480 V, 500 V and 6001) V ranges ACS 601 (IP 54) ACS 604 frame sizes R7 to R9 480 V, 500 V and 6001) V ranges ACS 604 480 V, 500 V and 6001) V parallel connected units
1)

UL/CSA Markings

UL x x x x

ULC x x x pending

CSA x x x pending

the approval is valid up to 600 V

UL

ACS 600 is suitable for use in a circuit capable of delivering not more than 65 kA rms symmetrical amperes at 480 V maximum (500 V units), and at 600 V maximum (690 V units). ACS 600 provides overload protection in accordance with the National Electrical Code (US). See ACS 600 Firmware Manual for setting. Default setting is off, must be activated at start-up. ACS 600 drives are to be used in a heated indoor controlled environment. See subsection Ambient Conditions for specific limits. ACS 600 braking chopper - ABB has braking chopper modules that, when applied with appropriately sized braking resistors, will allow the drive to dissipate regenerative energy (normally associated with quickly decelerating a motor). Proper application of the braking chopper is defined in the NBRA-6xx Braking Choppers Installation and Start Up Guide, Appendix A. These guide lines will allow you to size braking choppers to your specific application needs for standard or extended duty cycles. This can be applied to a single drive or multiple drives with DC Bus connected to allow a sharing of regenerative energy.

“C-tick” Marking

“C-tick” marking is required in Australia and New Zealand. A “C-tick” mark is attached to ACx 601/607 frequency converters to verify that the unit follows the provisions of ? Radiocommunications (Electromagnetic Compatibililty) Standard 1998 ? Radiocommunications (Compliance Labelling - Incidental Emissions) Notice 1998 ? AS/NZS 2064: 1997. Limits and methods of measurement of electronic disturbance characteristics of industrial, scientific and medical (ISM) radiofrequency equipment. ? Radiocommunication Regulations of New Zealand (1993).

Compliance with AS/ NZS 2064

The above rules define the essential requirements for emissions of electrical equipment used in Australia and New Zealand. The standard AS/NZS 2064 (Limits and methods of measurement of electronic disturbance characteristics of industrial, scientific and medical radiofrequency equipment, 1997) covers the detailed requirements for three-phase frequency converters.

A-30

ACS/ACC/ACP 604/6x7 Frequency Converters

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data
The ACx 607 frequency converters comply with AS/NZS 2064 for class A equipment (suitable for use in all establishments other than domestic and those directly connected to a low-voltage network which supplies buildings used for domestic purposes). The compliance is valid with the following provisions: 1. The ACx 600 is equipped with EMC filtering (refer to Table A-1). 2. The ACx 607 is installed according to the instructions given in this manual. 3. The motor and control cables are selected as specified in this manual. 4. Maximum cable length is 100 metres. Note: The ACx 600 must not be equipped with EMC filtering (refer to Table A-1) when installed to IT networks. The mains becomes connected to earth potential through the EMC filter capacitors. In IT networks this may cause danger or damage the unit.

Equipment Warranty and Liability

General: ABB warrants the Equipment supplied by ABB against defects in material and workmanship for a period of twelve (12) months after installation or twenty four (24) months from date of shipment from factory, whichever first occurs. Should any failure to conform with the applicable warranties appear during the specified periods under normal and proper use and provided the Equipment has been properly stored, installed, operated and maintained, and if given prompt notice by Purchaser, ABB shall correct such nonconformity, at its option; by (1) repair or replacement of the nonconforming equipment or parts thereof. Repairs or replacements pursuant to warranty shall not renew or extend the applicable original equipment warranty period, provided however, that any such repairs or replacement of equipment or parts thereof shall be warranted for the time remaining of the original warranty period or 30 days, whichever is longer. ABB shall not be responsible for providing working access to the defect, including disassembly and reassembly of equipment or for providing transportation to and from repair or factory facility, all of which shall be at Purchaser’s risk and expense. These warranties shall not apply to any Equipment or parts thereof which (1) have been improperly repaired or altered; (2) have been subjected to misuse, negligence or accident; (3) have been used in a manner contrary to ABB’s instructions; (4) are comprised of materials provided or designed stipulated by Purchaser; or (5) are used equipment. The foregoing warranties are exclusive and in lieu of all other warranties of quality and performance, written, oral or implied, and all other warranties including any implied warranties of merchantability or fitness for a particular purpose are hereby disclaimed by ABB and all equipment manufacturers. Correction of nonconformities in the manner and for the period of time provided above shall be the Purchaser’s exclusive remedy and shall constitute fulfilment of all liabilities of ABB and any Equipment manufacturer (including any liability for direct, indirect, special, incidental or consequential damages) whether in warranty, contract, negligence, tort, strict liability, or otherwise with respect to any nonconformance of or defect or deficiency in the equipment supplied or services furnished hereunder.

ACS/ACC/ACP 604/6x7 Frequency Converters

A-31

Appendix A – ACS/ACC/ACP 604/6x7 Technical Data

Limitation of Liability

IN NO EVENT SHALL ABB, ITS SUPPLIERS OR SUBCONTRACTORS BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES, WHETHER IN CONTRACT, WARRANTY, TORT, NEGLIGENCE, STRICT LIABILITY OR OTHERWISE, including, but not limited to loss of profits or revenue, loss of use of the Equipment or any associated equipment, cost of capital, cost of substitute equipment, facilities or services, downtime costs, delays, or claims of customers of the Purchaser or other third parties for such or other damages. ABB’s liability on any claim whether in contract, warranty, negligence, tort, strict liability, or otherwise for any loss or damage arising out of, connected with, or resulting from the contract or the performance or breach thereof, or from the design, manufacture, sale, delivery, resale, repair, replacement, installation, technical direction of installation, inspection, operation or use of any equipment covered by or in connection therewith, shall in no case exceed the purchase price of the Equipment or part thereof or services which give rise to the Claim. All clauses of action against ABB arising out of or relating to the contract or the performance or breach hereof shall expire unless brought within one year of the time of accrual thereof. In no event, regardless of cause, shall ABB assume responsibility for or be liable for penalties or penalty clauses of any description or for indemnification of customer or others for costs, damages, or expenses each arising out of or related to the goods or services of the order. Your local distributor or ABB office may hold different guarantee details, which are specified in the sales terms, conditions, or guarantee terms. These terms are available on request. If you have any questions concerning your ABB frequency converter, please contact the local distributor or ABB office. The technical data, information and specifications are valid at the time of printing. The manufacturer reserves the right to modifications without prior notice.

A-32

ACS/ACC/ACP 604/6x7 Frequency Converters

ABB Industry Oy Drives P.O. Box 184 FIN-00381 HELSINKI FINLAND Telephone +358 10 22 2000 Telefax +358 10 22 22681 Internet http://www.abb.com/automation

ABB Automation Inc. Drives & Power Products 16250 West Glendale Drive New Berlin, WI 53151 USA Telephone 262 785-8378 800 243-4384 Telefax 262 780-5135

3AFY 61201394 R0525 REV D EFFECTIVE: 15.6.2001 EN


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