ABB ACS 800 Series User manual

ACS800
Hardware Manual
ACS800-31 Drives (5.5 to 110 kW)
ACS800-U31 Drives (7.5 to 125 HP)
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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)
3AFE64382101 (English)
ACS800-01/U1 Marine Supplement 3AFE64291275 (English)
ACS800-02/U2 Hardware Manual 90 to 500 kW (125 to 600 HP)
3AFE64567373 (English)
ACS800-11/U11 Hardware Manual 5.5 to110 kW (7.5 to 125 HP)
3AFE68367883 (English)
ACS800-31/U31 Hardware Manual 5.5 to110 kW (7.5 to 125 HP)
3AFE68599954 (English)
ACS800-04 Hardware Manual 0.55 to 132 kW
3AFE68372984 (English)
ACS800-04/04M/U4 Hardware Manual 45 to 560 kW (60 to
600 HP) 3AFE64671006 (English)
ACS800-04/04M/U4 Cabinet Installation 45 to 560 kW (60 to
600 HP) 3AFE68360323 (English)
ACS800-07/U7 Hardware Manual 45 to 560 kW (50 to 600 HP)
3AFE64702165 (English)
ACS800-07/U7 Dimensional Drawings 45 to 560 kW (50 to
600 HP) 3AFE64775421
ACS800-07 Hardware Manual 500 to 2800 kW
3AFE64731165 (English)
ACS800-17 Hardware Manual 75 to 1120 kW
3AFE64681338 (English)
ACS800-37 Hardware Manual 160 to 2800 kW (200 to 2700 HP)
3AFE68557925 (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)
Pump Control Application Program Firmware Manual
3AFE68478952 (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.
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ACS800-31 Drives
5.5 to 110 kW
ACS800-U31 Drives
7.5 to 125 HP
Hardware Manual
3AFE68599954 Rev A EN
EFFECTIVE: 14.10.2005
©2005 ABB Oy. All Rights Reserved.
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Update Notice
1
Update Notice
NEW (page 6): Safety / Installation and maintenance work
• 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 Safe torque off function (option +Q967) does not remove the voltage from the
main and auxiliary circuits.
NEW (page 10): Safety / Operation
• 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.
NEW (page 20): Contents
•Installation of ASTO board (Safe torque off, +Q967) describes the electrical
installation of the optional Safe torque off function.
CHANGED (page 22): Installation and commissioning flowchart
See Electrical installation, Motor control and I/O board (RMIO), Installation of AGPS
board (Prevention of Unexpected Start, +Q950), Installation of ASTO board (Safe
torque off, +Q967) and the optional module manual delivered with the module.
The notice concerns the following ACS800-31 Drives (5.5
to 110 kW) and ACS800-U31 Drives (7.5 to 125 HP)
Hardware Manuals:
Code: 3AUA0000059448 Rev B
Valid: from 01.09.2010 until the release of the next revision of
the manual
Contents:
The headings in this update notice refer to the modified
subsections in the original English manual. Each heading also
includes a page number and a classifier NEW, CHANGED, or
DELETED. The page number refers to the page number in the
original English manual. The classifier describes the type of
the modification.
Code Revision Language
3AFE68599954 AEnglish EN
3AFE68626552 AGerman DE
3AFE68626561 AFrench FR
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Update Notice
2
NEW (page 31): Type code
The table below contains the new option code definition for the Safe torque off
function.
NEW (page 49): Emergency stop
Note: If you add or modify the wiring in the drive safety circuits, ensure that the
appropriate standards (e.g. IEC 61800-5-1, EN 62061, EN/ISO 13849-1 and -2) and
the ABB guidelines are met. After making the changes, verify the operation of the
safety function by testing it.
NEW (page 51): Safe torque off
The drive supports the Safe torque off (STO) function according to standards
EN 61800-5-2:2007; EN/ISO 13849-1:2008, IEC 61508, and EN 62061:2005. The
function also corresponds to an uncontrolled stop in accordance with category 0 of
EN 60204-1 and prevention of unexpected start-up of EN 1037.
The STO may be used where power removal is required to prevent an unexpected
start. The function disables the control voltage of the power semiconductors of the
drive output stage, thus preventing the inverter from generating the voltage required
to rotate the motor (see the diagram below). By using this function, short-time
operations (like cleaning) and/or maintenance work on non-electrical parts of the
machinery can be performed without switching off the power supply to the drive.
Code Description
+Q967 Safe torque off (STO)
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Update Notice
3
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Update Notice
4
WARNING! The Safe torque off function does not disconnect the voltage of the main
and auxiliary circuits from the drive. Therefore maintenance work on electrical parts
of the drive or the motor can only be carried out after isolating the drive system from
the main supply.
Note: The Safe torque off function can be used for stopping the drive in emergency
stop situations. In the normal operating mode, use the Stop command instead. If a
running drive is stopped by using the function, the drive will trip and stop by coasting.
If this is not acceptable, e.g. causes danger, the drive and machinery must be
stopped using the appropriate stopping mode before using this function.
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
function, the drive system can produce an alignment torque which maximally rotates
the motor shaft by 180/pdegrees. pdenotes the pole pair number.
Note: If you add or modify the wiring in the drive safety circuits, ensure that the
appropriate standards (e.g. IEC 61800-5-1, EN 62061, EN/ISO 13849-1 and -2) and
the ABB guidelines are met. After making the changes, verify the operation of the
safety function by testing it.
NEW (page 75): Installation of ASTO board (Safe torque off, +Q967)
What this chapter contains
This chapter describes
• electrical installation of the optional Safe torque off function (+Q967) of the drive.
• specifications of the board.
Safe torque off (+Q967)
The optional Safe torque off function includes an ASTO board, which is connected to
the drive and an external power supply. See also chapter Planning the electrical
installation, page 50.
Installation of the ASTO board
WARNING! Dangerous voltages can be present at the ASTO board even when the
24 V supply is switched off. Follow the Safety instructions on the first pages of this
manual and the instruction in this chapter when working on the ASTO board.
Make sure that the drive is disconnected from the mains (input power) and the
24 V source for the ASTO board is switched off during installation and
maintenance. If the drive is already connected to the mains, wait for 5 min after
disconnecting mains power.
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Update Notice
5
See
• page 24 for location of terminal block X41 of the drive
• page 6(in this Update Notice) for the circuit diagram
• page 6(in this Update Notice) for the dimensions of the ASTO-11C board
• section ASTO-11C in chapter Technical data for the technical data of the ASTO-
11C board.
Note: Maximum cable length between ASTO terminal block X2 and the drive
terminal block is restricted to 3 metres.
Connect the ASTO board as follows:
• Remove the cover of the enclosed ASTO unit by undoing the fixing screws (1).
• Ground the ASTO unit via the bottom plate of the enclosure or via terminal X1:2
or X1:4 of the ASTO board.
• Connect the cable delivered with the kit between terminal block X2 of the ASTO
board (2) and drive terminal block X41.
• Connect a cable between connector X1 of the ASTO board (3) and the 24 V
source.
• Fasten the cover of the ASTO unit back with screws.
1
2
3
X2
X1
24 V
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Update Notice
6
Circuit diagram
The diagram below shows the connection between the ASTO board and the drive
when it is ready. For an example diagram of a complete Safe torque off circuit, see
page 3(in this Update Notice).
Dimensions
The dimensions of the ASTO board are the same as the dimensions of the AGPS
board. See Dimensional drawing on page 74.
NEW (page 111): ASTO-11C
Nominal input voltage 24 V DC
Nominal input current 40 mA (20mA per channel)
X1 terminal sizes 4 x 2.5 mm2
Nominal output current 0.4 A
X2 terminal block type JST B4P-VH
Ambient temperature 0...50°C
Relative humidity Max. 90%, no condensation allowed
Dimensions (with
enclosure) 167 x 128 x 52 mm (Height x Weight x Depth)
Weight (with enclosure) 0.75 kg
3AUA0000069101
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Update Notice
7
NEW (page 111): Ambient conditions
Modules with option +Q967: the installation site altitude in operation is 0 to 2000 m.
Operation
installed for stationary use
Installation site altitude [...]
Modules with option +Q967
: 0 to 2000 m
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Update Notice
8
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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.
To which products this chapter applies
This chapter applies to the ACS800-01/U1, ACS800-11/U11, ACS800-31/U31,
ACS800-02/U2 and ACS800-04/04M/U4 of frame sizes R7 and R8.
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.
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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.
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.
•ACS800-02 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.
•ACS800-04M, ACS800-07: The Prevention of Unexpected Start function 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.
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Safety instructions
7
Grounding
These instructions are intended for all who are responsible for the grounding of the
drive.
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).
•ACS800-01, ACS800-11, ACS800-31: 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.
ACS800-04 (45 to 560 kW) and ACS800-02 in first environment: make a 360°
high frequency grounding of motor cable entries at the cabinet lead-through.
•Do not install a drive with EMC filter option +E202 or +E200 (available for
ACS800-01 and ACS800-11, ACS800-31 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.
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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.
•ACS800-01, ACS800-11, ACS800-31: 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.
Use extreme caution when manoeuvring a drive that runs on wheels. An
overturning unit can cause physical injury.
•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!
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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.).
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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 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.
•ACS800-04M, ACS800-07: 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 .
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Safety instructions
11
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.
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.
• 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 (U1, V1, W1, U2, V2, W2, UDC+, UDC-).
Alternative 2) Measure that there is no voltage present on the drive input or output
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 may damage or explode the capacitors in the intermediate circuit
of the drive.
Controlling a permanent magnet motor is only allowed using the ACS800 Permanent
Magnet Synchronous Motor Drive Application Program, or other application
programs in scalar control mode.
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Safety instructions
12
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