ABB ACS 800 Series User manual

ACS800
Hardware Manual
ACS800-01 Drives (0.55 to 200 kW)
ACS800-U1 Drives (0.75 to 200 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)
ACS800-01/U1 Drives Hardware Manual (0.55 to 200 kW, 0.75 to
200 hp) 3AFE64382101
Converter module capacitor reforming instructions 3BFE64059629
ACS800-01, -U1, -04 frames R2-R6 EMC filter disconnection 3AXD00000168163
Drive firmware manuals and guides
ACS800 Standard Control Program 7.x Firmware Manual and
Adaptive Program Application Guide
3AFE64527592
3AFE64527274
ACS800 Permanent Magnet Synchronous Machine Drive Control
Program Supplement to Firmware Manual for ACS800 Standard
Control Program 7.x
3AFE68437890
ACS800 Master/Follower Application Guide 3AFE64590430
ACS800 Pump Control Application Program 7.2 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/U1/04 + C132 Drives (0.55 to 200 kW, 0.75 to 200
hp) Marine Supplement
3AFE68291275
ACS800-01/04/11/31/104/104LC Safe torque off function
(+Q967), Application guide 3AUA0000063373
AIMA-01 I/O Module Adapter User's Manual 3AFE64661442
ACS800 Vibration Damper Installation Guide 3AFE68295351
Manuals and quick guides for I/O extension modules, fieldbus
adapters, etc.
ACS800-01/U1 manuals

ACS800-01 Drives
0.55 to 200 kW
ACS800-U1 Drives
0.75 to 200 hp
Hardware Manual
3AFE64382101 Rev K
EN
EFFECTIVE: 2013-06-27
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.
Hot surface warning warns of hot surfaces which can cause physical
injury.

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 or on the optional
AGPS board (Prevention of unexpected start-up).

Safety instructions
7
Grounding
These instructions are intended for all who are responsible for the grounding of the
drive.
•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.
•At installation sites above 2000 m (6562 ft), the terminals of the RMIO board
and option 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,
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 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).
•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.
•Do not install a drive with EMC filter option +E202 or +E200 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. In addition, we recommend that you use:
• a cross-section of the protective earthing conductor of at least 10 mm2Cu or
16 mm2Al,
or
• an automatic disconnection of the supply in case of discontinuity of the
protective earthing conductor,
or
• a second protective earthing conductor of the same cross-sectional area as
the original protective earthing conductor.

Safety instructions
8
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:
•Handle the unit carefully.
•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 borings and grindings 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.
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
9
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; 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
10
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.
Note: Controlling a permanent magnet motor is only allowed using the ACS800
Permanent Magnet Synchronous Motor Drive Control Program.
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. Prevent the start-up of any
drives in the same mechanical group by opening the Prevention of unexpected
start switch (option +Q950) or the Safe torque off switch (option +Q967) 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, output or DC
terminals (U1, V1, W1, U2, V2, W2, UDC+, UDC-).
Alternative 2) Measure that there is no voltage present on the drive input, output
or DC 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 can damage the capacitors in the intermediate circuit of the drive.