ABB ACS800-U7 Bedienungsanleitung

ACS800

Hardware Manual

ACS800-07 Drives (45 to 560 kW)

ACS800-U7 Drives (50 to 600 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)

ACS800-07/U7 Dimensional Drawings 45 to 560 kW (50 to 600 hp) 3AFE64775421

ACS800-07 (+V992) drives (500-2800 kW) Hardware Manual 3AUA0000068936

Drive firmware manuals and guides

Standard Control Program Firmware Manual 3AFE64527592

System Control Program Firmware Manual 3AFE64670646

Control Program Template Firmware Manual 3AFE64616340

Master/Follower Application Guide Supplement to Firmware Manual for

ACS800 Standard Application Program 3AFE64590430

Pump Control Program Firmware Manual 3AFE68478952

Extruder Control Program Supplement 3AFE64648543

Centrifuge Control Program Supplement 3AFE64667246

Traverse Control Program Supplement 3AFE64618334

Crane Control Program Firmware Manual 3BSE11179

Adaptive Programming Application Guide 3AFE64527274

Option manuals and guides

Safety options for ACS800 cabinet-installed drives (+Q950, +Q951, +Q952,

+Q963, +Q964, +Q967 and +Q968) Wiring, start-up and operation

instructions

3AUA0000026238

Cabinet Options for ACS800-07/U7/17/37 Description 3AUA0000053130

ACS800-07 Drives (45 to 560 kW) Air Intake from Below Kit Installation

Instructions 3AFE68505241

ATEX-certified thermal motor protection functions for ACS800 cabinet-

installed drives (+L513+Q971 and +L514+Q971) Safety, wiring, start-up and

operation instructions

3AUA0000082378

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

ACS800-07 Drives

45 to 560 kW

ACS800-U7 Drives

50 to 600 hp

Hardware Manual

3AFE64702165 Rev H

EFFECTIVE: 2012-09-19

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.

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 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

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 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).

Safety instructions

Grounding

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

drive.

•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).

•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 +Q968) 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 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 or

equipment malfunction and increase electromagnetic interference.

•Ground the drive, the 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).

•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

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:

•Cover the drive when installing to ensure that dust from borings and grindings

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 centre of gravity.

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

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

supply.

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 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 .

Safety instructions

Permanent magnet synchronous motor

These are additional warnings concerning permanent magnet synchronous motor

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

equipment.

Installation and maintenance work

WARNING! Do not work on the drive when the permanent magnet synchronous

motor is rotating. Also, when the supply power is switched off and the inverter is

stopped, a rotating permanent magnet synchronous 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-up switch (option +Q950) or Safe torque off switch (option +Q968) 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 or output

terminals (L1, L2, L3, U2, V2, W2, UDC+, UDC-).

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

terminals (L1, L2, L3, 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 may damage or explode the capacitors in the intermediate circuit

of the drive.

Controlling a permanent magnet synchronous motor is only allowed using the control

program for Permanent Magnet Synchronous Machine Drive.

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

(option +Q968) or the Prevention of unexpected start-up (option +Q950) function,

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

motor shaft by 180/pdegrees. p denotes the pole pair number.

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