ABB ACS 800 Series User manual

ACS800
Hardware Manual
ACS800-PC Drives (150 to 600 HP)

2
ACS800 Single Drive Manuals
HARDWARE MANUALS
(appropriate manual is included in the delivery)
ACS800-04/U4 Hardware Manual 90 to 500 kW (125 to
600 HP) 3AFE64671006 (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)
PFC Application Program Firmware Manual
3AFE64649337 (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.

ACS800-PC Drives
150 to 600 HP
Hardware Manual
3AUA0000010601 Rev. C
EFFECTIVE: 10/16/2009
2009 ABB Inc. All Rights Reserved.

5
Safety Instructions
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.
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.
Special note or recommendation. This symbol is used to highlight
especially important information or recommendation for product
application.

6
Safety Instructions
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.
WARNING!
•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 switching off the power, always wait for 5 minutes 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 L1, L2 and L3 and the frame is close to
0 V.
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 disconnecting device (means) of the drive does not isolate the input cables
and busbars from the main AC supply. Before working inside the cabinet,
isolate the input cables and busbars from the main supply with the
disconnecting device at the distribution board or with the disconnector of the
supply transformer.
•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.
•The Prevention of Unexpected Start function does not remove the voltage from
the main and auxiliary circuits.

7
Safety Instructions
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.
WARNING!
•Cover the drive when installing to ensure that dust from drilling or foreign
objects do not enter the drive. Electrically conductive dust inside the unit may
cause damage or lead to malfunction.
•Ensure sufficient cooling.
•Welding of the cabinet frame is not recommended. However, if electric welding
is the only way to mount the cabinet, follow the instructions given in chapter
"Mechanical Installation". Ensure that welding fumes are not inhaled. If the
welding return wire is connected improperly, the welding circuit may damage
electronic circuits in the cabinet.
•When removing the module from the cabinet and manoeuvring it outside the
cabinet, prevent it from toppling over by securing it. The drive module is heavy
and has a high center of gravity.

8
Safety Instructions
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.
Fiber 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.).
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 with EMC filter option +E202 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.

9
Safety Instructions
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 (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.
•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 .

10
Safety Instructions
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
Before installation and maintenance work on the drive:
• Disconnect the motor from the drive with a safety switch
and additionally if possible (or)
• lock the motor shaft and ground the motor connection terminals temporarily by
connecting them together as well as to the PE. Before grounding, measure that
the motor is de-energized.
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.