ABB ACS 800 Series User manual

ACS800
Hardware Manual
ACS800-11 Drives (5.5 to 110 kW)
ACS800-U11 Drives (7.5 to 125 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)
ACS800-11/U11 Drives Hardware Manual (5.5 to 110 kW, 7.5 to 125 hp) 3AFE68367883
Drive firmware manuals and guides
ACS800 Standard Control Program Firmware Manual and
Adaptive Program Application Guide
3AFE64527592
3AFE64527274
ACS800 IGBT Supply Control Program Firmware Manual 3AFE68315735
ACS800 System Control Program Firmware Manual and
Adaptive Program Application Guide
3AFE64670646
3AFE68420075
ACS800 Permanent Magnet Synchronous Machine Control Program
Supplement to Firmware Manual for System Control Program
3AFE64492641
ACS800 Permanent Magnet Synchronous Machine Drive Control Program
Supplement to Firmware Manual for ACS800 Standard Control Program
3AFE68437890
ACS800 Crane Control Program Firmware Manual 3AFE68775230
ACS800 Master/Follower Application Guide 3AFE64590430
ACS800 Pump Control Application Program 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
ACS800-01/04/11/31/104/104LC Safe torque off function (+Q967),
Application guide 3AUA0000063373
RDCO-01/02/03 DDCS Communication Option Modules 3AFE64492209
AIMA-01 I/O Module Adapter User's Manual 3AFE64661442
NBRA-6xx Braking Choppers Installation and Start-up Guide 3AFY58920541
ACS800 Vibration Damper Installation Guide 3AFE68295351
Manuals and quick guides for I/O extension modules, fieldbus adapters, etc.
ACS800-11/U11 manuals

ACS800-11 Drives
5.5 to 110 kW
ACS800-U11 Drives
7.5 to 125 hp
Hardware Manual
3AFE68367883 Rev C
EN
EFFECTIVE: 2013-03-04
2013 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, 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.

Safety instructions
6
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.

Safety instructions
7
Grounding
These instructions are intended for all who are responsible for the grounding of the
drive.
•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 and EN 61800-5-1.
•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.
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 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).
•ACS800-11: 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.
•Drives with EMC filter option +E202 or +E200 are not suitable for use in an IT
system (an ungrounded power system or a high-resistance-grounded [over
30 ohms] power system). Before connecting the drive to the power system,
disconnect the EMC filter capacitors as described in section IT (ungrounded)
systems on page 70.
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 61800-5-1, 4.3.5.5.2), a fixed protective earth connection is
required.

Safety instructions
8
Mechanical installation and maintenance
These instructions are intended for all who install and service the drive.
WARNING! Ignoring the following instructions can cause physical injury or death,
or damage to the equipment:
•Handle the unit carefully.
•ACS800-11: 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 drilling 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.
Do not tilt!

Safety instructions
9
Printed circuit boards
Fibre optic cables
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
10
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 (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.
•The Safe torque off function (option +Q967) can be used for stopping the drive
in emergency stop situations. In the normal operating mode, use the Stop
command instead.
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 .