ABB ACS 600 Series User manual

ACS/ACC/ACP 604/607 AC Drives

75 to 700 HP

(55 to 630 kW)

ACS 600

ACS 600 Hardware Manual

This manual includes

•Safety

• Installation

• Maintenance

• Product Information

ACS/ACC/ACP 604/607 AC Drives

75 to 700 HP

(55 to 630 kW)

Hardware Manual

This manualconcerns the ACS 607,ACC 607,

andACP 607 and the ACS604, ACC 604 and

ACP604 AC Drives. In the text, they are

collectively referred to as ACx604/607.

ACS607-5.0-US-04

3AUA489002B4974R0101 REVA

EFFECTIVE: 10/1/98

SUPERSEDES: None

ACS/ACC/ACP 604/607 AC Drives ACx = ACS/ACC/ACP iii

Safety Instructions

Overview

This chapter states the safety instructions which must be followed

when installing, operating and servicing the ACS 600. If neglected,

physical injury and death may follow, or damage may occur to the AC

drive, the motor and driven equipment. The material in this chapter

must be studied before attempting any work on, or with, the unit.

Warnings and Notes

This manual distinguishes two sorts of safety instructions. Warnings

are used to inform of conditions which can, if proper steps are not

taken, lead to a serious fault condition, physical injury and death. Notes

are used when the reader is required to pay special attention or when

there is additional information available on the subject. Notes are less

crucial than Warnings, but should not be disregarded.

Warnings

Warnings are provided in the instruction manuals and on labels

attached to the AC drive. Readers are informed of situations that can

result in serious physical injury and/or serious damage to equipment

with the following symbols:

Notes

Notes are provided in the instruction manuals to notify readers of the

need for special attention or additional information available on the

subject with the following symbols:

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! Caution aims to draw special attention to a

particular issue.

Note:

Note gives additional information or points out

more information available on the subject.

Safety Instructions

iv ACx = ACS/ACC/ACP ACS/ACC/ACP 604/607 AC Drives

Installation and

Maintenance Safety

These safety instructions are intended for all work on the ACX 600. In

addition to the instructions given below, there are more safety

instructions on the first pages of the appropriate hardware manual.

WARNING! All electrical installation and maintenance work on the ACX

600 should be carried out by qualified electricians.

The ACX 600 and adjoining equipment must be properly grounded.

Do not attempt any work on a powered ACS 600. After switching off the

power, always allow the intermediate circuit capacitors 5 minutes to

discharge before working on the drive, the motor or the motor cable. It

is good practice to check (with a voltage indicating instrument) that the

drive is in fact discharged before beginning work.

The ACX 600 motor cable terminals are at a dangerously high voltage

when power is applied, regardless of motor operation.

The brake control terminals (UDL & UDC, R+ and R- terminals) carry a

dangerous DC voltage (over500V).

There can be dangerous voltages inside the ACX 600 from external

control circuits when the ACX 600 input power is shut off. Exercise

appropriate care when working with the unit. Neglecting these

instructions can cause physical injury and death.

WARNING! The ACS 600 introduces electric motors, drive train

mechanisms and driven machines to an extended operating range.

The ACS 600 can be adjusted to operate the motor at speeds above

and below the speed provided by connecting the motor directly to the

power line. Before adjusting the drive and putting it into service, make

sure that the motor and all driven equipment is suitable for operation

throughout the speed range provided by the AC drive.

WARNING! If an external source for start command is selected and it is

ON, the ACS 600 will start immediately after fault reset unless the drive

is configured for 3-wire Start/Stop.

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

WARNING! There are several automatic reset functions in the ACX

600. If selected, they reset the unit and resume operation after a fault.

These functions should not be selected if other equipment is not

Safety Instructions

ACS/ACC/ACP 604/607 AC Drives ACx = ACS/ACC/ACP v

compatible with this kind of operation, or dangerous situations can be

caused by such action.

Supply Connections

ACx 607 units include a door interlocked fused disconnect. This switch

does not switch off the power from the EMC Line Filter of ACS/ACC

607-0400-3, -0490-3/5/6, -0610-3/5/6 and -0760-5/6 units. For ACS/

ACC 607-0400-3, -0490-3/5/6, -0610-3/5/6 and -0760-5/6 units with

EMC Line Filter, and for the ACx 604 module an input power

disconnecting means must be installed between the ac power source

and the ac drive. The disconnecting means must conform to applicable

safety regulations. The disconnecting means must be locked to the

open position during installation and maintenance work.

If an ACx 607 with the integrated EMC filter (code 0 or 3 in the type

code for EMC Filters) is connected to an ungrounded power system or

high resistance grounded power system (over 30 Ohms), the power

line will be connected to ground potential through the EMC filter

capacitors of the ACx 601. This may cause danger or damage the unit.

Disconnect the EMC filter capacitors before connecting the ACx 601 to

an ungrounded power system. For detailed instructions on how to do

this, please contact your local ABB distributor.

Ground Fault

Protective Function

The ACx 600 (with Standard and Motion Control Application Programs)

is equipped with an internal ground fault protective function to protect

the unit against ground faults in the drive, the motor and the motor

cable. This is not a personal safety or a fire protection feature. The

earth fault protective function of the ACS/ACP 600 can be disabled by

Parameter 30.17 (ACC: 30.11).

The internal earth fault protective function is not in use in the 12-pulse

supplied units. For ACS 62x units, refer to

ACS 600 Power Extension

Range Supplement

ACS 600 Converter Module Installation in User-

defined Cabinet

The EMC filter of the ACx 600 includes capacitors connected between

the power circuit and the chassis. These capacitors increase the

ground leakage current from the AC line through the ground (PE)

connection and may cause some ground fault current circuit breakers

to trip.

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 an option for ACx 607.

Safety Instructions

vi ACx = ACS/ACC/ACP ACS/ACC/ACP 604/607 AC Drives

Motor Connections

WARNING! Operation is not allowed if the motor nominal voltage is

less than one half 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.

WARNING! Do not make any voltage tolerance or insulation resistance

test (Hi Pot or Megger) on any part of the ACx 600. Disconnect motor

wires before making any tests of the motor or the cables between the

drive and motor.

Motor Insulation

Requirements

As with all AC drives employing the most modern IGBT invertor

technology, the output waveform of the ACx 600 consists of a series of

rectangular voltage pulses. Regardless of the output frequency, the

voltage of the pulses is approximately 1.35 times the input line voltage

with a very short rise time.

The voltage of the pulses can be almost double at the motor terminals,

depending on the properties of the cable between the drive and the

motor. This in turn can cause additional stress to the motor insulation.

The motor manufacturer should be consulted regarding the

characteristics of the motor insulation system. Failure of the motor to

fulfill the following requirements may shorten its life.

Safety Instructions

ACS/ACC/ACP 604/607 AC Drives ACx = ACS/ACC/ACP vii

The following table lists the insulation requirements for motors used

with ACx 600 AC drives.

Motor Type Nominal

AC Line Voltage Motor Insulation Requirement

ABB Motors

(manufactured

from beginning of

1998)

N< 500 V Standard insulation system

525 V <

N≤690 V Standard insulation and dv/dt filter

special insulation system

Random-wound

Motors

N≤ 420 V Motor insulation system must withstand

VPK

= 1300 V.

420 V <

N≤500 V If motor insulation system withstands

VPK

= 1600 V and 0.2

µs rise time, a dv/dt filter is not needed.

With a dv/dt filter at the output of the ACx 600, motor

insulation system must withstand

VPK

= 1300 V.

500 V <

N≤600 V Motor insulation system must withstand

VPK

= 1600 V. A

dv/dt filter must be used at the output of the ACx 600.

600 V <

N≤690 V Motor insulation system must withstand

VPK

= 1800 V. A dv/dt filter must be used at the output of the

ACx 600.

Form-wound

Motors

N≤690 V If motor insulation system withstands

VPK

= 2000 V and rise

time 0.3 µs, no dv/dt filter is needed.

Symbol Definition

Nnominal mains voltage

VPK

peak line to line voltage at motor terminals

Rise time:

= 0.8 ·

VPK

/(dv/dt)

Rise time is line to line voltage change rate

at motor terminals (the interval during

which the voltage changes from 10% to

90 % of the whole voltage range)

VPK

and

depend on cable length. Read

the values of

VPK

and dv/dt from the

diagrams below.

Safety Instructions

viii ACx = ACS/ACC/ACP ACS/ACC/ACP 604/607 AC Drives

Without Filter

Below is a diagram of

and

dv/dt

as a function of cable length when

no dv/dt filter is used.

With dv/dt Filter

Below is a diagram of

and

dv/dt

as a function of cable length with

dv/dt filter at the output of the ACx 600.

Power Factor

Correction Capacitors

Power factor correction capacitors and surge absorbers must not be

connected between the drive and the motor. These devices are not

designed to be used with AC drives, 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.

0,5

1,5

2,5

3,5

4,5

0 50 100 150 200 250 300

dv/dt / (kV/µs)

VPK/ VN

Cable length

1000

500

(m)

(feet)

0,5

1,5

2,5

3,5

4,5

0 50 100 150 200 250 300

dv/dt / (kV/µs)

VPK / VN

1000

500 (feet)

(m)

Cable length

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