ABB ACS 800 Series Manual de usuario

ACS800

Hardware Manual

ACS800-01 Drives (0.55 to 200 kW)

ACS800-U1 Drives (0.75 to 200 hp)

List of related manuals

You can find manuals and other product documents in PDF format on the Internet. See section

Document library on the Internet on the inside of the back cover. For manuals not available in the

Document library, contact your local ABB representative.

Drive hardware manuals and guides Code (English)

ACS800-01/U1 Drives Hardware Manual (0.55 to 200 kW, 0.75 to

200 hp) 3AFE64382101

Converter module capacitor reforming instructions 3BFE64059629

ACS800-01, -U1, -04 frames R2-R6 EMC filter disconnection 3AXD00000168163

Drive firmware manuals and guides

ACS800 Standard Control Program 7.x Firmware Manual and

Adaptive Program Application Guide

3AFE64527592

3AFE64527274

ACS800 Permanent Magnet Synchronous Machine Drive Control

Program Supplement to Firmware Manual for ACS800 Standard

Control Program 7.x

3AFE68437890

ACS800 Master/Follower Application Guide 3AFE64590430

ACS800 Pump Control Application Program 7.2 Firmware

Manual

3AFE68478952

ACS800 Extruder Control Program Supplement 3AFE64648543

ACS800 Centrifuge Control Program Supplement 3AFE64667246

ACS800 Traverse Control Program Supplement 3AFE64618334

ACS800 Winch Control Program (+N698) Firmware Manual 3AUA0000031177

ACS800 Rod Pump Light Control Program Firmware Manual 3AUA0000005304

etc.

Option manuals and guides

ACS800-01/U1/04 + C132 Drives (0.55 to 200 kW, 0.75 to 200

hp) Marine Supplement

3AFE68291275

ACS800-01/04/11/31/104/104LC Safe torque off function

(+Q967), Application guide 3AUA0000063373

AIMA-01 I/O Module Adapter User's Manual 3AFE64661442

ACS800 Vibration Damper Installation Guide 3AFE68295351

Manuals and quick guides for I/O extension modules, fieldbus

adapters, etc.

ACS800-01/U1 manuals

ACS800-01 Drives

0.55 to 200 kW

ACS800-U1 Drives

0.75 to 200 hp

Hardware Manual

3AFE64382101 Rev K

EFFECTIVE: 2013-06-27

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.

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.

•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 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-up).

Safety instructions

Grounding

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

drive.

•The Prevention of unexpected start-up function (option +Q950) does not

remove the voltage from the main and auxiliary circuits.

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

the main and auxiliary circuits.

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

and option 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).

•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.

•Do not install a drive with EMC filter option +E202 or +E200 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. In addition, we recommend that you use:

• a cross-section of the protective earthing conductor of at least 10 mm2Cu or

16 mm2Al,

• an automatic disconnection of the supply in case of discontinuity of the

protective earthing conductor,

• a second protective earthing conductor of the same cross-sectional area as

the original protective earthing conductor.

Safety instructions

Mechanical installation and maintenance

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

Printed circuit boards

Fibre optic cables

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

or damage to the equipment:

•Handle the unit carefully.

•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.

•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.

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; 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 .

Safety instructions

Permanent magnet motor

These are additional warnings concerning permanent magnet motor drives. Ignoring

the instructions can cause physical injury or death, or damage to the equipment.

Note: Controlling a permanent magnet motor is only allowed using the ACS800

Permanent Magnet Synchronous Motor Drive Control Program.

Installation and maintenance work

WARNING! Do not work on the drive when the permanent magnet motor is rotating.

Also, when the supply power is switched off and the inverter is stopped, a rotating

permanent magnet motor feeds power to the intermediate circuit of the drive and the

supply connections become live.

Before installation and maintenance work on the drive:

• Stop the 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.

• Ensure that there is no voltage on the drive power terminals:

Alternative 1) Disconnect the motor from the drive with a safety switch or by other

means. Measure that there is no voltage present on the drive input, output or DC

terminals (U1, V1, W1, U2, V2, W2, UDC+, UDC-).

Alternative 2) Measure that there is no voltage present on the drive input, output

or DC terminals (U1, V1, W1, U2, V2, W2, UDC+, UDC-). Ground the drive output

terminals temporarily by connecting them together as well as to the PE.

Alternative 3) If possible, both of the above.

Start-up and operation

WARNING! Do not run the motor over the rated speed. Motor overspeed leads to

overvoltage which can damage the capacitors in the intermediate circuit of the drive.

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