ABB ACS 800 Series Bedienungsanleitung

ACS800

Hardware Manual

ACS800-PC Drives (150 to 600 HP)

ACS800 Single Drive Manuals

HARDWARE MANUALS

(appropriate manual is included in the delivery)

ACS800-04/U4 Hardware Manual 90 to 500 kW (125 to

600 HP) 3AFE64671006 (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 Application Program Firmware Manual

3AFE64527592 (English)

System Application Program Firmware Manual

3AFE63700177 (English)

Application Program Template Firmware Manual

3AFE64616340 (English)

Master/Follower 3AFE64590430 (English)

PFC Application Program Firmware Manual

3AFE64649337 (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-PC Drives

150 to 600 HP

Hardware Manual

3AUA0000010601 Rev. C

EFFECTIVE: 10/16/2009

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, the 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.

Special note or recommendation. This symbol is used to highlight

especially important information or recommendation for product

application.

Safety Instructions

Installation and Maintenance Work

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

Ignoring the instructions can cause physical injury or death.

WARNING!

•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 switching off the power, always wait for 5 minutes to let the intermediate

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

the motor cable.

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

that:

1.Voltage between drive input phases L1, L2 and L3 and the frame is close to

0 V.

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 disconnecting device (means) of the drive does not isolate the input cables

and busbars from the main AC supply. Before working inside the cabinet,

isolate the input cables and busbars from the main supply with the

disconnecting device at the distribution board or with the disconnector of the

supply transformer.

•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.

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

the main and auxiliary circuits.

Safety Instructions

WARNING! 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!

•Cover the drive when installing to ensure that dust from drilling or foreign

objects do not enter the drive. Electrically conductive dust inside the unit may

cause damage or lead to malfunction.

•Ensure sufficient cooling.

•Welding of the cabinet frame is not recommended. However, if electric welding

is the only way to mount the cabinet, follow the instructions given in chapter

"Mechanical Installation". Ensure that welding fumes are not inhaled. If the

welding return wire is connected improperly, the welding circuit may damage

electronic circuits in the cabinet.

•When removing the module from the cabinet and manoeuvring it outside the

cabinet, prevent it from toppling over by securing it. The drive module is heavy

and has a high center of gravity.

Safety Instructions

Grounding

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

drive. Incorrect grounding can cause physical injury, death or equipment malfunction

and increase electromagnetic interference.

Fiber Optic Cables

WARNING! 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.).

WARNING!

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

safety in all circumstances, and to reduce electromagnetic emission and pick-

up.

•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).

•Do not install a drive with EMC filter option +E202 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

Operation

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

the drive. Ignoring the instructions can cause physical injury or death or damage the

equipment.

WARNING!

•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 Application

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.

•Do not use the optional Prevention of Unexpected Start function for stopping

the drive when the drive is running. Give a Stop command instead.

Note:

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

Standard Application 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.

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.

Installation and Maintenance Work

Before installation and maintenance work on the drive:

• Disconnect the motor from the drive with a safety switch

and additionally if possible (or)

• lock the motor shaft and ground the motor connection terminals temporarily by

connecting them together as well as to the PE. Before grounding, measure that

the motor is de-energized.

Operation

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

which may explode the capacitors in the intermediate circuit of the drive.

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