ABB ACS800-04 User manual

ACS800

Hardware Manual

ACS800-04 and ACS800-04M Drive Modules (45 to 560 kW)

ACS800-U4 Drive Modules (60 to 600 HP)

ACS800 Single Drive Manuals

HARDWARE MANUALS (appropriate manual is included in the

delivery)

ACS800-01/U1 Hardware Manual 0.55 to 160 kW (0.75 to 200 HP)

3AFE64382101 (English)

ACS800-01/U1/04 Marine Supplement 0.55 to 160 kW (0.75 to

200 HP) 3AFE64291275 (English)

ACS800-11/U11 Hardware Manual 5.5 to 110 kW (7.5 to 125 HP)

3AFE68367883 (English)

ACS800-31/U31 Hardware Manual 5.5 to110 kW (7.5 to 125 HP)

3AFE68599954 (English)

ACS800-02/U2 Hardware Manual 90 to 500 kW (125 to 600 HP)

3AFE64567373 (English)

ACS800-04/U4 Hardware Manual 0.55 to 160 kW (0.75 to 200 HP)

3AFE68372984 (English)

ACS800-04/04M/U4 Hardware Manual 45 to 560 kW (60 to

600 HP) 3AFE64671006 (English)

ACS800-04/04M/U4 Cabinet Installation 45 to 560 kW (60 to

600 HP) 3AFE68360323 (English)

ACS800-07/U7 Hardware Manual 45 to 560 kW (50 to 600 HP)

3AFE64702165 (English)

ACS800-07/U7 Dimensional Drawings 45 to 560 kW (50 to

600 HP) 3AFE64775421

ACS800-07 Hardware Manual 500 to 2800 kW

3AFE64731165 (English)

ACS800-17 Hardware Manual 55 to 2500 kW (75 to 2800 HP)

3AFE68397260 (English)

ACS800-37 Hardware Manual 55 to 2700 kW (75 to 3000 HP)

3AFE68557925 (English)

• Safety instructions

• Electrical installation planning

• Mechanical and electrical installation

• Motor control and I/O board (RMIO)

• Maintenance

• Technical data

• Dimensional drawings

• Resistor braking

FIRMWARE MANUALS, SUPPLEMENTS AND GUIDES

(appropriate documents are included in the delivery)

Standard Control Program Firmware Manual

3AFE64527592 (English)

System Control Program Firmware Manual

3AFE64670646 (English)

Control Program Template Firmware Manual

3AFE64616340 (English)

Master/Follower 3AFE64590430 (English)

Pump Control Program Firmware Manual

3AFE68478952 (English)

Extruder Control Program Supplement 3AFE64648543 (English)

Centrifuge Control Program Supplement 3AFE64667246 (English)

Traverse Control Program Supplement 3AFE64618334 (English)

Crane Control Program Firmware Manual 3BSE11179 (English)

Adaptive Programming Application Guide

3AFE64527274 (English)

OPTION MANUALS (delivered with optional equipment)

Fieldbus Adapters, I/O Extension Modules etc.

ACS800-04 and ACS800-04M Drive Modules

45 to 560 kW

ACS800-U4 Drive Modules

60 to 600 HP

Hardware Manual

3AFE64671006 Rev F EN

EFFECTIVE: 15.6.2007

Safety instructions

What this chapter contains

This chapter contains the safety instructions which you must follow when installing,

operating and servicing the drive. If ignored, physical injury or death may follow, or

damage may occur to the drive, motor or driven equipment. Read the safety

instructions before you work on the unit.

To which products this chapter applies

This chapter applies to the ACS800-01/U1, ACS800-11/U11, ACS800-31/U31,

ACS800-02/U2 and ACS800-04/04M/U4 of frame sizes R7 and R8.

Use of warnings and notes

There are two types of safety instructions throughout this manual: warnings and

notes. Warnings caution you about conditions which can result in serious injury or

death and/or damage to the equipment. They also tell you how to avoid the danger.

Notes draw attention to a particular condition or fact, or give information on a

subject. The warning symbols are used as follows:

Dangerous voltage warning warns of high voltage which can cause

physical injury and/or damage to the equipment.

General warning warns about conditions, other than those caused by

electricity, which can result in physical injury and/or damage to the

equipment.

Electrostatic discharge warning warns of electrostatic discharge which

can damage the equipment.

Hot surface warning warns of hot surfaces which can cause physical

injury.

Safety instructions

Installation and maintenance work

These warnings are intended for all who work on the drive, motor cable or motor.

WARNING! Ignoring the following instructions can cause physical injury or death, or

damage to the equipment:

•Only qualified electricians are allowed to install and maintain the drive.

•Never work on the drive, motor cable or motor when main power is applied.

After disconnecting the input power, always wait for 5 min to let the intermediate

circuit capacitors discharge before you start working on the drive, motor or

motor cable.

Always ensure by measuring with a multimeter (impedance at least 1 Mohm)

that:

1. voltage between drive input phases U1, V1 and W1 and the frame is close to

0V.

2. voltage between terminals UDC+ and UDC- and the frame is close to 0 V.

•Do not work on the control cables when power is applied to the drive or to the

external control circuits. Externally supplied control circuits may cause

dangerous voltages inside the drive even when the main power on the drive is

switched off.

•Do not make any insulation or voltage withstand tests on the drive or drive

modules.

•When reconnecting the motor cable, always check that the phase order is

correct.

Note:

•The motor cable terminals on the drive are at a dangerously high voltage when

the input power is on, regardless of whether the motor is running or not.

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

dangerous DC voltage (over 500 V).

•Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V)

may be present on the terminals of relay outputs RO1 to RO3 or on the optional

AGPS board (Prevention of Unexpected Start, ACS800-01/U1, ACS800-04/

04M, ACS800-11/U11, ACS800-31/U31).

•ACS800-02 with enclosure extension: The main switch on the cabinet door

does not remove the voltage from the input busbars of the drive. Before working

on the drive, isolate the whole drive from the supply.

•ACS800-01/U1, ACS800-04/04M, ACS800-11/U11, ACS800-31/U31: The

Prevention of Unexpected Start function does not remove the voltage from the

main and auxiliary circuits.

Safety instructions

Grounding

These instructions are intended for all who are responsible for the grounding of the

drive.

•At installation sites above 2000 m (6562 ft), the terminals of the RMIO board

and optional modules attached to the board do not fulfil the Protective Extra

Low Voltage (PELV) requirements stated in EN 50178.

WARNING! Ignoring the following instructions can cause physical injury, death,

increased electromagnetic interference and equipment malfunction:

•Ground the drive, motor and adjoining equipment to ensure personnel safety in

all circumstances, and to reduce electromagnetic emission and interference.

•Make sure that grounding conductors are adequately sized as required by

safety regulations.

•In a multiple-drive installation, connect each drive separately to protective

earth (PE).

•ACS800-01, ACS800-11, ACS800-31: In European CE compliant installations

and in other installations where EMC emissions must be minimized, make a

360° high frequency grounding of cable entries in order to suppress

electromagnetic disturbances. In addition, connect the cable shields to

protective earth (PE) in order to meet safety regulations.

ACS800-04 (45 to 560 kW) and ACS800-02 in first environment: make a 360°

high frequency grounding of motor cable entries at the cabinet lead-through.

•Do not install a drive with EMC filter option +E202 or +E200 (available for

ACS800-01 and ACS800-11, ACS800-31 only) on an ungrounded power

system or a high-resistance-grounded (over 30 ohms) power system.

Note:

•Power cable shields are suitable for equipment grounding conductors only

when adequately sized to meet safety regulations.

•As the normal leakage current of the drive is higher than 3.5 mA AC or 10 mA

DC (stated by EN 50178, 5.2.11.1), a fixed protective earth connection is

required.

Safety instructions

Mechanical installation and maintenance

These instructions are intended for all who install and service the drive.

WARNING! Ignoring the following instructions can cause physical injury or death,

or damage to the equipment:

•Handle the unit carefully.

•ACS800-01, ACS800-11, ACS800-31: The drive is heavy. Do not lift it alone.

Do not lift the unit by the front cover. Place the unit only on its back.

ACS800-02, ACS800-04: The drive is heavy. Lift the drive by the lifting lugs

only. Do not tilt the unit. The unit will overturn from a tilt of about 6 degrees.

Use extreme caution when manoeuvring a drive that runs on wheels. An

overturning unit can cause physical injury.

•Beware of hot surfaces. Some parts, such as heatsinks of power

semiconductors, remain hot for a while after disconnection of the electrical

supply.

•Make sure that dust from borings and grindings does not enter the drive when

installing. Electrically conductive dust inside the unit may cause damage or

malfunctioning.

•Ensure sufficient cooling.

•Do not fasten the drive by riveting or welding.

Do not tilt!

Safety instructions

Printed circuit boards

Fibre optic cables

WARNING! Ignoring the following instructions can cause damage to the printed

circuit boards:

•The printed circuit boards contain components sensitive to electrostatic

discharge. Wear a grounding wrist band when handling the boards. Do not

touch the boards unnecessarily.

WARNING! Ignoring the following instructions can cause equipment malfunction

and damage to the fibre optic cables:

•Handle the fibre optic cables with care. When unplugging optic cables, always

grab the connector, not the cable itself. Do not touch the ends of the fibres with

bare hands as the fibre is extremely sensitive to dirt. The minimum allowed

bend radius is 35 mm (1.4 in.).

Safety instructions

Operation

These warnings are intended for all who plan the operation of the drive or operate

the drive.

WARNING! Ignoring the following instructions can cause physical injury or death,

or damage to the equipment:

•Before adjusting the drive and putting it into service, make sure that the motor

and all driven equipment are suitable for operation throughout the speed range

provided by the drive. The drive can be adjusted to operate the motor at

speeds above and below the speed provided by connecting the motor directly

to the power line.

•Do not activate automatic fault reset functions of the Standard Control Program

if dangerous situations can occur. When activated, these functions will reset

the drive and resume operation after a fault.

•Do not control the motor with the disconnecting device (disconnecting means);

instead, use the control panel keys and , or commands via the I/O

board of the drive. The maximum allowed number of charging cycles of the DC

capacitors (i.e. power-ups by applying power) is five in ten minutes.

Note:

•If an external source for start command is selected and it is ON, the drive (with

Standard Control Program) will start immediately after fault reset unless the

drive is configured for 3-wire (a pulse) start/stop.

•When the control location is not set to Local (L not shown in the status row of

the display), the stop key on the control panel will not stop the drive. To stop

the drive using the control panel, press the LOC/REM key and then the stop

key .

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