ABB ACS800-37-0060-3 User manual

ACS800
Hardware Manual
ACS800-37 Drives (55 to 2700 kW / 75 to 3000 HP)

ACS800-37 Drives
55 to 2700 kW (75 to 3000 HP)
Hardware Manual
3AFE68557925 REV B EN
EFFECTIVE: 01.11.2005
©2005 ABB Oy. All Rights Reserved.

Safety instructions
5
Safety instructions
What this chapter contains
This chapter contains safety instructions 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.
Usage 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, and advise on 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 voltages 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, or damage the
equipment.
WARNING!
•Only qualified electricians are allowed to install and maintain the drive.
•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.
•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. Measure the voltage between terminals UDC+
and UDC- (L+ and L–) with a multimeter (impedance at least 1 Mohm) to
ensure that the drive is discharged before beginning work.
•Apply temporary grounding before working on the unit.
•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 to exist inside the drive even when the main power of 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.
•When joining shipping splits (if any), check the cable connections at the joints
before switching on the supply voltage.
•Live parts on the inside of the doors are protected against direct contact.
Special attention shall be paid when handling metallic shrouds.
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 relay outputs of the drive system.
•The Prevention of Unexpected Start function does not remove the voltage from
the main and auxiliary circuits.

Safety instructions
7
WARNING!
•During the installation procedure, supply, filter or inverter modules may have to
be temporarily extracted from the cabinet. The modules have a high centre of
gravity. In order to minimise the danger of toppling over, keep the support legs
(if provided) of the modules extended whenever manoeuvring the modules
outside the cabinet. An overturning module can cause physical injury.
•Electrically conductive dust inside the unit may cause damage or lead to
malfunction. Make sure that dust from drilling does not enter the drive when
installing.
•Fastening the cabinet by riveting or welding is not recommended. However, if
welding is necessary, ensure the return wire is properly connected in order not
to damage the electronic equipment in the cabinet. Also ensure that welding
fumes are not inhaled.
•Ensure sufficient cooling of the unit.
•Cooling fans may continue to rotate for a while after the disconnection of the
electrical supply.
•Some parts inside the drive cabinet, such as heatsinks of power
semiconductors, remain hot for a while after the disconnection of the electrical
supply.
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.
Do not tilt!

Safety instructions
8
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!
•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 equipped with an EMC (line) filter to 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.
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 25 mm (1 in.).

Safety instructions
9
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 (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 Prevention of Unexpected Start feature for stopping the drive
when the inverter unit(s) 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 immediatelyafter 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
10
Permanent magnet motor drives
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, a rotating permanent magnet motor
feeds power to the intermediate circuit of the drive and also the supply connections
become live (even when the inverter is stopped!).
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 above the rated speed. Motor overspeed leads to overvoltage
which may result in explosion of the capacitors in the intermediate circuit of the drive.
Application program
Controlling a permanent magnet motor is only allowed using the ACS800 Permanent
Magnet Synchronous Motor Drive Application Program, or using other application
programs in scalar control mode only.