ABB ACS800-02 User manual

ACS800
Hardware Manual
ACS800-02 Drives (45 to 500 kW)
ACS800-U2 Drives (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 110 kW (0.75 to 150 HP)
3AFE 64382101 (English)
ACS800-02/U2 Hardware Manual 45 to 500 kW (60 to 600 HP)
3AFE 64567373 (English)
ACS800-04/04M/U4 Hardware Manual 45 to 560 kW (60 to
600 HP) 3AFE 64671006 (English)
ACS800-07/U7 Hardware Manual 45 to 560 kW (50 to 600 HP)
3AFE 64702165 (English)
ACS800-07/U7 Dimensional Drawings 45 to 560 kW (50 to
600 HP) 3AFE 64775421
ACS800-07 Hardware Manual 500 to 2800 kW
3AFE 64731165 (English)
ACS800-17 Hardware Manual 75 to 1120 kW
3AFE 64681338 (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
3AFE 64527592 (English)
System Application Program Firmware Manual
3AFE 63700177 (English)
Application Program Template Firmware Manual
3AFE 64616340 (English)
Master/Follower 3AFE 64590430 (English)
PFC Application Program Firmware Manual
3AFE 64649337 (English)
Extruder Control Program Supplement 3AFE 64648543 (English)
Centrifuge Control Program Supplement
3AFE 64667246 (English)
Traverse Control Program Supplement 3AFE 64618334 (English)
Crane Control Program Firmware Manual 3BSE 11179 (English)
Adaptive Programming Application Guide
3AFE 64527274 (English)
OPTION MANUALS (delivered with optional equipment)
Fieldbus Adapters, I/O Extension Modules etc.

ACS800-02 Drives
45 to 500 kW
ACS800-U2 Drives
60 to 600 HP
Hardware Manual
3AFE 64567373 Rev C EN
EFFECTIVE: 18.11.2003
ã2003 ABB Oy. All Rights Reserved.

Safety instructions
5
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.
To which products this chapter applies
This chapter applies to the ACS800-01/U1, the ACS800-02/U2 and the ACS800-04/
U4.
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.

Safety instructions
6
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.
Only qualified electricians are allowed to install and maintain the drive.
•Never work on the drive, the motor cable or the motor when main power is
applied. After switching off the input power, always wait for 5 min 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 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.
•ACS800-04: the busbar ends on both sides of the pedestal are at a
dangerously high voltage when the input power is on, regardless of whether the
motor is running or not.
•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.

Safety instructions
7
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.
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.
Fibre 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.).
•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).
•ACS800-01: 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.
(ACS800-02: 360° high frequency grounding of cable entries is not required at
the drive end.)
•Do not install a drive with EMC filter option +E202 or +E200 (available for
ACS800-01 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
8
Mechanical installation
These notes are intended for all who install the drive. Handle the unit carefully to
avoid damage and injury.
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.
•ACS800-01: 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.
•Make sure that dust from drilling does not enter the drive when installing.
Electrically conductive dust inside the unit may cause damage or lead to
malfunction.
•Ensure sufficient cooling.
•Do not fasten the drive by riveting or welding.
•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 (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 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
9
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
• Disconnect the motor from the drive with a safety switch
and additionally if possible
• lock the motor shaft and ground the motor connection terminals temporarily by
connecting them together as well as to the PE.
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.

Safety instructions
10