ABB ACS800-U4 User manual

ACS800

Hardware Manual

ACS800-04 Drive Modules (0.55 to 200 kW)

ACS800-U4 Drive Modules (0.75 to 200 HP)

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]

ACS800 Single Drive Manuals

HARDWARE MANUALS (appropriate manual is included in the

delivery)

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

3AFE64382101 (English)

ACS800-01/U1/04 Marine Supplement 0.55 to 200 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 200 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.

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]

ACS800-04 Drive Modules

0.55 to 200 kW

ACS800-U4 Drive Modules

0.75 to 200 HP

Hardware Manual

3AFE68372984 Rev E EN

EFFECTIVE: 31.03.2008

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]

Update Notice

NEW (page 6): Safety / Installation and maintenance work

• After maintaining or modifying a drive safety circuit or changing circuit boards

inside the module, retest the functioning of the safety circuit according to the

start-up instructions.

• Do not change the electrical installations of the drive except for the essential

control and power connections. Changes may affect the safety performance or

operation of the drive unexpectedly. All customer-made changes are on the

customer's responsibility.

[...]

Note:

• The Safe torque off function (option +Q967) does not remove the voltage from the

main and auxiliary circuits.

CHANGED (page 10): Safety / Permanent magnet motor

• Ensure that the motor cannot rotate during work. Prevent the start-up of any

drives in the same mechanical group by opening the Prevention of unexpected

start switch (option +Q950) or the Safe torque off switch (option +Q967) and

padlocking it. Make sure that no other system, like hydraulic crawling drives, are

able to rotate the motor directly or through any mechanical connection like felt,

nip, rope, etc.

NEW (page 21): Terms and abbreviations

The following term has been added to the Terms and abbreviations table:

The notice concerns the following ACS800-04 Drive

Modules (0.55 to 200 kW) and ACS800-U4 Drive Modules

(0.75 to 200 HP) Hardware Manuals:

Code: 3AUA0000068979 Rev B

Valid: from 01.09.2010 until the release of the next revision of

the manual

Contents:

The headings in this update notice refer to the modified

subsections in the original English manual. Each heading also

includes a page number and a classifier NEW, CHANGED, or

DELETED. The page number refers to the page number in the

original English manual. The classifier describes the type of

the modification.

Term/

Abbreviation Explanation

ASTO An optional board within inverter modules used to implement the Safe torque off

function (option +Q967).

Code Revision Language

3AFE68372984 EEnglish EN

3AFE68449995 EGerman DE

3AFE68449979 ESpanish ES

3AFE68450004 EFrench FR

3AFE68449987 EItalian IT

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]

Update Notice

NEW (page 24): Type code

The table below contains the new option code definition for the Safe torque off

function.

CHANGED (page 25): Main circuit and control / Diagram

X41 - Prevention of unexpected start (+Q950, AGPS board) or Safe torque off

(+Q967, ASTO board)

NEW (page 49): Emergency stop

Note: If you add or modify the wiring in the drive safety circuits, ensure that the

appropriate standards (e.g. IEC 61800-5-1, EN 62061, EN/ISO 13849-1 and -2) and

the ABB guidelines are met. After making the changes, verify the operation of the

safety function by testing it.

NEW (page 51): Safe torque off

The drive supports the Safe torque off (STO) function according to standards

EN 61800-5-2:2007; EN/ISO 13849-1:2008, IEC 61508, and EN 62061:2005. The

function also corresponds to an uncontrolled stop in accordance with category 0 of

EN 60204-1 and prevention of unexpected start-up of EN 1037.

The STO may be used where power removal is required to prevent an unexpected

start. The function disables the control voltage of the power semiconductors of the

drive output stage, thus preventing the inverter from generating the voltage required

to rotate the motor (see the diagram below). By using this function, short-time

operations (like cleaning) and/or maintenance work on non-electrical parts of the

machinery can be performed without switching off the power supply to the drive.

Code Description

+Q967 Safe torque off (STO)

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]

Update Notice

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]

Update Notice

WARNING! The Safe torque off function does not disconnect the voltage of the main

and auxiliary circuits from the drive. Therefore maintenance work on electrical parts

of the drive or the motor can only be carried out after isolating the drive system from

the main supply.

Note: The Safe torque off function can be used for stopping the drive in emergency

stop situations. In the normal operating mode, use the Stop command instead. If a

running drive is stopped by using the function, the drive will trip and stop by coasting.

If this is not acceptable, e.g. causes danger, the drive and machinery must be

stopped using the appropriate stopping mode before using this function.

Note concerning permanent magnet motor drives in case of a multiple IGBT

power semiconductor failure: In spite of the activation of the Safe torque off

function, the drive system can produce an alignment torque which maximally rotates

the motor shaft by 180/pdegrees. pdenotes the pole pair number.

Note: If you add or modify the wiring in the drive safety circuits, ensure that the

appropriate standards (e.g. IEC 61800-5-1, EN 62061, EN/ISO 13849-1 and -2) and

the ABB guidelines are met. After making the changes, verify the operation of the

safety function by testing it.

CHANGED (pages 67-68): Connecting the control cables / Terminals

Frame sizes R2 to R4:

X41 - Terminal for optional Prevention of unexpected start (+Q950) or optional Safe

torque off (+Q967)

Frame sizes R5 and R6:

X41 for Prevention of unexpected start (+Q950, AGPS board) or for Safe torque off

(+Q967, ASTO board)

NEW (page 77): Safe torque off (+Q967), ASTO board

WARNING! Dangerous voltages can be present at the ASTO board even when the

24 V supply is switched off. Follow the Safety instructions on the first pages of this

manual and the instruction in this chapter when working on the ASTO board.

Make sure that the drive is disconnected from the mains (input power) and the

24 V source for the ASTO board is switched off during installation and

maintenance. If the drive is already connected to the mains, wait for 5 min after

disconnecting mains power.

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]

Update Notice

Connect the optional ASTO board as follows:

• Remove the cover of the enclosed ASTO unit by undoing the fixing screws (1).

• Ground the ASTO unit via the bottom plate of the enclosure or via terminal X1:2

or X1:4 of the ASTO board.

• Connect the cable delivered with the kit between terminal block X2 of the ASTO

board (2) and drive terminal block X41.

• Connect a cable between connector X1 of the ASTO board (3) and the 24 V

source.

• Fasten the cover of the ASTO unit back with screws.

Note: Location of the X41 terminal block varies according to the drive frame size,

see page 67.

Note: Maximum cable length between ASTO terminal block X2 and drive terminal

block is restricted to 3 m.

For technical data, see section ASTO-11C in chapter Technical data.

24 V

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Update Notice

The diagram below shows the connection between the ASTO board and the drive

when it is ready. For an example diagram of a complete Safe torque off circuit, see

page 3(in this Update Notice).

NEW (page 84): Installation check-list

The following step has been added to the ELECTRICAL INSTALLATION procedure:

Modules with the Safe torque off option (+967) only (ASTO board): The Safe torque off

circuit is completed and the supply voltage for ASTO-11C board is 24 V.

3AUA0000069101

Phone: 800.894.0412 - Fax: 888.723.4773 - Web: www.clrwtr.com - Email: [email protected]

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