ABB ACS800 Series Hardware Manual
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ABB ACS800 Series Hardware Manual

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ACS800
Hardware Manual
Safety Options +Q950, +Q951, +Q952 and +Q954 for
ACS800-02+C111 Drives (45 to 560 kW)
ACS800-U2 Drives (60 to 600 HP)
ACS800-07 Drives (45 to 2800 kW)
ACS800-U7 Drives (50 to 600 HP)
ACS800-17 Drives (160 to 2500 kW)
ACS800-37 Drives (160 to 2700 kW)
Q950
Prevention of Unexpected Start
=
Q951
Category 0 emergency stop
=
Q952
Category 1 emergency stop
=
Q954
Earth fault monitoring for IT (ungrounded) systems
=
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Summary of Contents for ABB ACS800 Series

  • Page 1 ACS800 Hardware Manual Safety Options +Q950, +Q951, +Q952 and +Q954 for ACS800-02+C111 Drives (45 to 560 kW) ACS800-U2 Drives (60 to 600 HP) ACS800-07 Drives (45 to 2800 kW) ACS800-U7 Drives (50 to 600 HP) ACS800-17 Drives (160 to 2500 kW) ACS800-37 Drives (160 to 2700 kW) Q950 Prevention of Unexpected Start...

  • Page 2: Acs800 Single Drive Manuals

    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/U1/04 Marine Supplement 0.55 to 132 kW (0.75 to 150 HP) 3AFE64291275 (English) ACS800-02/U2 Hardware Manual 90 to 560 kW (125 to 600 HP) 3AFE64567373 (English) ACS800-11/U11 Hardware Manual 5.5 to110 kW (7.5 to 125 HP) 3AFE68367883 (English)
  • Page 3 ACS800-U2 Drives (60 to 600 HP) ACS800-07 Drives (45 to 2800 kW) ACS800-U7 Drives (50 to 600 HP) ACS800-17 Drives (160 to 2500 kW) ACS800-37 Drives (160 to 2700 kW) Hardware Manual 3AFE68578027 Rev A EN EFFECTIVE: 21.6.2005 © 2005 ABB Oy. All Rights Reserved.

  • Page 5: Table Of Contents

    Table of contents ACS800 Single Drive Manuals ........... . . 2 Table of contents About this manual What this chapter contains .
  • Page 6 Category 0 emergency stop for ACS800-07/17/37 (+Q951, n×R8i) What this chapter contains ............21 To which drives this chapter applies .
  • Page 7 Description ..............52 Category 1 definition .
  • Page 8 Table of contents...

  • Page 9: About This Manual

    About this manual This manual contains descriptions and installation, use and maintenance instructions for the following safety options: Drive type Option code Description ACS800-07 +Q950 Prevention of Unexpected Start ACS800-U7 ACS800-17 ACS800-37 ACS800-02+C111 +Q951 Category 0 emergency stop ACS800-02+C127 ACS800-U2 ACS800-07 ACS800-U7 ACS800-17...

  • Page 10: Safety

    Safety Only qualified specialists are allowed to install, commission and maintain the safety options. WARNING! Follow the safety instructions 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.

  • Page 11: Contents

    Literature references Safety handbook [code: 1 SAC 103 201 H 0201 (English)] by ABB STOTZ- KONTAKT GmbH contains general information on regulations and standards, available on the Internet www.abb.com.
  • Page 12 About this manual...

  • Page 13: What This Chapter Contains

    Prevention of Unexpected Start for ACS800- 07/U7/17/37 (+Q950) What this chapter contains This chapter describes the Prevention of Unexpected Start function (+Q950). The chapter deals with wiring, operation and use. An example circuit diagram is included. To which drives this chapter applies The chapter applies to the following drives: Drive type Frame sizes...

  • Page 14: Wiring

    • EN 954-1:1996 “Safety of machinery – Safety-related parts of control systems – Part 1: General principles for design” • EN ISO 13849-2:2003 “Safety of machinery – Safety-related parts of control systems – Part 2: Validation”. Wiring Install on a control desk near the machinery: •...

  • Page 15: Circuit Diagram

    Circuit diagram An example circuit diagram of the factory wiring is shown below. See the circuit diagram delivered with the drive for the actual terminal markings. Prevention of Unexpected Start for ACS800-07/U7/17/37 (+Q950)
  • Page 16 Prevention of Unexpected Start for ACS800-07/U7/17/37 (+Q950)

  • Page 17: What This Chapter Contains

    Category 0 emergency stop for ACS800-02/U2/07/ U7/17/37 (+Q951, R6, R6i, R7, R7i, R8) What this chapter contains This chapter describes the category 0 emergency stop function (+Q951). The chapter deals with applicability, wiring, operation and use. An example circuit diagram is included. To which drives this chapter applies The chapter applies to the following drives: Drive type...

  • Page 18: Applicable Standards

    Applicable standards The emergency stop complies with the following standards: • IEC/EN 60204-1:1997 “Safety of machinery – Electrical equipment of machines – Part 1: General requirements”. • EN 418:1992 “Safety of machinery – Emergency stop equipment, functional aspects – Principles for design” •...

  • Page 19: Use

    How to activate the emergency stop Push the emergency stop push-button. The emergency stop activates and the button locks in the “ON” position. How to deactivate the emergency stop WARNING! Ensure that it is safe to apply input voltage: • It is safe to start the motor. •...

  • Page 20: Circuit Diagram

    Circuit diagram An example circuit diagram of the factory wiring is shown below. See the circuit diagram delivered with the drive for the actual wiring. Category 0 emergency stop for ACS800-02/U2/07/U7/17/37 (+Q951, R6, R6i, R7, R7i, R8)

  • Page 21: Category 0 Emergency Stop For Acs800-07/17/37 (+Q951, N×R8I)

    Category 0 emergency stop for ACS800-07/17/37 (+Q951, n×R8i) What this chapter contains This chapter describes the category 0 emergency stop function (+Q951). The chapter deals with applicability, wiring, operation and use. Example circuit diagrams are included. To which drives this chapter applies The chapter applies to the following drives: Drive type Frame sizes...

  • Page 22: Applicable Standards

    Applicable standards The emergency stop complies with the following standards: • IEC/EN 60204-1:1997 “Safety of machinery – Electrical equipment of machines – Part 1: General requirements”. • EN 418:1992 “Safety of machinery – Emergency stop equipment, functional aspects – Principles for design”. •...

  • Page 23: Acs800-07 Units With Air Circuit Breaker

    ACS800-07 units with air circuit breaker The category 0 emergency stop, i.e. immediate removal of power, operates as follows: The user presses the emergency stop push-button. Contacts 33–34 open. Digital input DIIL on RMIO board de- Relay A21 de-energises. energises. Relay K14 de-energises ->...

  • Page 24: Acs800-17/37 Units

    ACS800-17/37 units The category 0 emergency stop, i.e. immediate removal of power, operates as follows. The user presses the emergency stop push-button. Digital input DIIL on the RMIO board of the Contacts 33–34 open. Relay A21 de-energises. motor-side converter de-energises. A21 contacts 13–14 in the line contactor control circuit open.

  • Page 25: Start-Up

    Start-up Setting of application program parameters is not needed. Parameter 21.09 START INTRL FUNC is set to OFF2 STOP at the factory. How to activate the emergency stop Push the emergency stop push-button. The emergency stop activates and the button locks in the “ON”...
  • Page 26 Step What to do What happens Give the drive a “start” command by the control panel (local ACS800-07: The drive starts and control active), I/O or serial communication link (external control accelerates to the speed defined by the active). active reference. Note: The “start”...

  • Page 27: Circuit Diagrams

    Circuit diagrams ACS800-07 units with line contactor (+F250+Q951) Example circuit diagrams of the factory wiring are shown below. See the circuit diagrams delivered with the drive for the actual wiring. Category 0 emergency stop for ACS800-07/17/37 (+Q951, n×R8i)
  • Page 28 Category 0 emergency stop for ACS800-07/17/37 (+Q951, n×R8i)
  • Page 29 Category 0 emergency stop for ACS800-07/17/37 (+Q951, n×R8i)

  • Page 30: Acs800-17 And Acs800-37 Units With Line Contactor (+F250+Q951)

    ACS800-17 and ACS800-37 units with line contactor (+F250+Q951) Example circuit diagrams of the factory wiring are shown below. See the circuit diagrams delivered with the drive for the actual wiring. Category 0 emergency stop for ACS800-07/17/37 (+Q951, n×R8i)
  • Page 31 Category 0 emergency stop for ACS800-07/17/37 (+Q951, n×R8i)
  • Page 32 Category 0 emergency stop for ACS800-07/17/37 (+Q951, n×R8i)
  • Page 33 Category 0 emergency stop for ACS800-07/17/37 (+Q951, n×R8i)

  • Page 34: Acs800-07 Units With Air Circuit Breaker (+F255+Q951)

    ACS800-07 units with air circuit breaker (+F255+Q951) Example circuit diagrams of the factory wiring are shown below. See the circuit diagrams delivered with the drive for the actual wiring. Category 0 emergency stop for ACS800-07/17/37 (+Q951, n×R8i)
  • Page 35 Category 0 emergency stop for ACS800-07/17/37 (+Q951, n×R8i)
  • Page 36 Category 0 emergency stop for ACS800-07/17/37 (+Q951, n×R8i)
  • Page 37 Category 0 emergency stop for ACS800-07/17/37 (+Q951, n×R8i)

  • Page 38: Acs800-17/37 Units With Air Circuit Breaker (+F255+Q951)

    ACS800-17/37 units with air circuit breaker (+F255+Q951) Example circuit diagrams of the factory wiring are shown below. See the circuit diagrams delivered with the drive for the actual wiring. Category 0 emergency stop for ACS800-07/17/37 (+Q951, n×R8i)
  • Page 39 Category 0 emergency stop for ACS800-07/17/37 (+Q951, n×R8i)
  • Page 40 Category 0 emergency stop for ACS800-07/17/37 (+Q951, n×R8i)

  • Page 41: What This Chapter Contains

    Category 1 emergency stop for ACS800-07/U7 (+Q952, R6, R7, R8) What this chapter contains This chapter describes the category 1 emergency stop function (+Q952). The chapter includes operation, user settings and example circuit diagrams. To which drives this chapter applies The chapter applies to the following drives Drive type Frame sizes...

  • Page 42: Applicable Standards

    Applicable standards The emergency stop complies with the following standards: • IEC/EN 60204-1:1997 “Safety of machinery – Electrical equipment of machines – Part 1: General requirements” • EN 418:1992 “Safety of machinery – Emergency stop equipment, functional aspects – Principles for design” •...

  • Page 43: Operation

    Operation The category 1 emergency stop, i.e. controlled emergency stop, operates as follows. User presses the emergency RDIO-01 = digital I/O extension module stop push-button. A21 = safety relay A22 = safety relay K21 = feedback response time relay K22 and K23 = tripping time relays Relay A21 de-energises and deactivates relays K21, K22, K23 and digital input DI2 of the RDIO...

  • Page 44: Wiring

    Wiring One emergency stop push-button is installed on the cabinet door and wired to the drive at the factory. Wire the additional emergency stop push-buttons to terminal block X8 (terminals 3, 4, 5 and 6) inside the drive cabinet. See the circuit diagram delivered with the drive.

  • Page 45: How To Deactivate The Emergency Stop

    How to deactivate the emergency stop WARNING! Ensure that it is safe to apply input voltage: • It is safe to start the motor. • All cabinet doors are closed. Step What to do What happens Turn the emergency stop push-button The emergency stop deactivates.

  • Page 46: Circuit Diagrams

    Circuit diagrams Example circuit diagrams below show the factory wiring. See the circuit diagrams delivered with the drive for the actual wiring. Category 1 emergency stop for ACS800-07/U7 (+Q952, R6, R7, R8)
  • Page 47 Category 1 emergency stop for ACS800-07/U7 (+Q952, R6, R7, R8)
  • Page 48 Category 1 emergency stop for ACS800-07/U7 (+Q952, R6, R7, R8)
  • Page 49 Category 1 emergency stop for ACS800-07/U7 (+Q952, R6, R7, R8)
  • Page 50 Category 1 emergency stop for ACS800-07/U7 (+Q952, R6, R7, R8)

  • Page 51: What This Chapter Contains

    Category 1 emergency stop for ACS800-07/17/37 (+Q952, R6i, R7i, n×R8i) What this chapter contains This chapter describes the category 1 emergency stop function (+Q952). The chapter deals with operation and user settings. Example circuit diagrams are included. To which drives this chapter applies The chapter applies to the following drives Drive type Frame sizes...

  • Page 52: Description

    Description Category 1 definition IEC/EN 60204-1 defines category 1 emergency stop as a controlled stop with the power to machine actuators available to achieve the stop and then removal of power when the stop is achieved. Implementation of category 1 stop in ACS800 in brief After the emergency stop command has been given, the drive first decelerates the motor to a standstill according to a preset ramp time.

  • Page 53: Components Of The Emergency Stop Function

    Components of the emergency stop function The following pieces of equipment are included: Line contactor or air circuit breaker. See Alternative drive configurations on page 54. Operating switch Position ACS800-07 ACS800-17/37 The supply rectifier stops and the line Cooling fans are disabled. (Other auxiliary contactor or air circuit breaker opens.

  • Page 54: Alternative Drive Configurations

    Alternative drive configurations ACS800-07 with line contactor Alternative 1 Diode supply module +F250 +F250 Line contactor DC bus Auxiliary voltage Alternative 2 Diode supply module +F253 +F260 +F250 +F250 Line contactor DC bus +F253 Switch- disconnector +F259 Earthing switch +F259 +F260 aR line fuses Auxiliary voltage...

  • Page 55: Acs800-17 And Acs800-37 Frame Sizes R6I, R7I And R8I

    ACS800-17 and ACS800-37 frame sizes R6i, R7i and R8i IGBT supply module +F250 Switch fuse DC bus +F250 Line contactor (optional in frame size R6i) Auxiliary voltage ACS800-17 and ACS800-37 with air circuit breaker (frame sizes 2×R8i and up) Air circuit breaker +F259 Earthing switch DC bus...

  • Page 56: Operation

    Operation The category 1 emergency stop, i.e. controlled emergency stop, operates as follows. RDIO-01 = digital I/O extension module A21 = safety relay User presses the emergency A22 = safety relay stop push-button. K21 = feedback response time relay K22 and K23 = tripping time relays Relay A21 de-energises and deactivates relays K21, K22, K23 and digital input DI2 of the RDIO...

  • Page 57: Wiring

    Wiring One emergency stop push-button is installed on the cabinet door and wired to the drive at the factory. Wire the additional emergency stop push-buttons to terminal block X8 (terminals 3, 4, 5 and 6) inside the drive cabinet. See the circuit diagram delivered with the drive.

  • Page 58: How To Deactivate The Emergency Stop

    How to deactivate the emergency stop WARNING! Ensure that it is safe to apply input voltage: • It is safe to start the motor. • All cabinet doors are closed. Step What to do What happens Turn the emergency stop push-button clockwise until the button The emergency stop deactivates.

  • Page 59: Circuit Diagrams

    Circuit diagrams ACS800-07 units with line contactor (+F250+Q952) Example circuit diagrams below show the factory wiring. See the circuit diagrams delivered with the drive for the actual wiring. Category 1 emergency stop for ACS800-07/17/37 (+Q952, R6i, R7i, n×R8i)
  • Page 60 Category 1 emergency stop for ACS800-07/17/37 (+Q952, R6i, R7i, n×R8i)
  • Page 61 Category 1 emergency stop for ACS800-07/17/37 (+Q952, R6i, R7i, n×R8i)
  • Page 62 Category 1 emergency stop for ACS800-07/17/37 (+Q952, R6i, R7i, n×R8i)
  • Page 63 Category 1 emergency stop for ACS800-07/17/37 (+Q952, R6i, R7i, n×R8i)
  • Page 64 Category 1 emergency stop for ACS800-07/17/37 (+Q952, R6i, R7i, n×R8i)

  • Page 65: Acs800-17 And Acs800-37 Units With Line Contactor (+F250+Q952)

    ACS800-17 and ACS800-37 units with line contactor (+F250+Q952) Example circuit diagrams below show the factory wiring. See the circuit diagrams delivered with the drive for the actual wiring. Category 1 emergency stop for ACS800-07/17/37 (+Q952, R6i, R7i, n×R8i)
  • Page 66 Category 1 emergency stop for ACS800-07/17/37 (+Q952, R6i, R7i, n×R8i)
  • Page 67 Category 1 emergency stop for ACS800-07/17/37 (+Q952, R6i, R7i, n×R8i)
  • Page 68 Category 1 emergency stop for ACS800-07/17/37 (+Q952, R6i, R7i, n×R8i)

  • Page 69: Acs800-07 Units With Air Circuit Breaker (+F255+Q952)

    ACS800-07 units with air circuit breaker (+F255+Q952) Example circuit diagrams below show the factory wiring. See the circuit diagrams delivered with the drive for the actual wiring. Category 1 emergency stop for ACS800-07/17/37 (+Q952, R6i, R7i, n×R8i)
  • Page 70 Category 1 emergency stop for ACS800-07/17/37 (+Q952, R6i, R7i, n×R8i)
  • Page 71 Category 1 emergency stop for ACS800-07/17/37 (+Q952, R6i, R7i, n×R8i)
  • Page 72 Category 1 emergency stop for ACS800-07/17/37 (+Q952, R6i, R7i, n×R8i)
  • Page 73 Category 1 emergency stop for ACS800-07/17/37 (+Q952, R6i, R7i, n×R8i)
  • Page 74 Category 1 emergency stop for ACS800-07/17/37 (+Q952, R6i, R7i, n×R8i)

  • Page 75: Acs800-17 And Acs800-37 Units With Air Circuit Breaker (+F255+Q952)

    ACS800-17 and ACS800-37 units with air circuit breaker (+F255+Q952) Example circuit diagrams below show the factory wiring. See the circuit diagrams delivered with the drive for the actual wiring. Category 1 emergency stop for ACS800-07/17/37 (+Q952, R6i, R7i, n×R8i)
  • Page 76 Category 1 emergency stop for ACS800-07/17/37 (+Q952, R6i, R7i, n×R8i)
  • Page 77 Category 1 emergency stop for ACS800-07/17/37 (+Q952, R6i, R7i, n×R8i)
  • Page 78 Category 1 emergency stop for ACS800-07/17/37 (+Q952, R6i, R7i, n×R8i)
  • Page 79 Category 1 emergency stop for ACS800-07/17/37 (+Q952, R6i, R7i, n×R8i)
  • Page 80 Category 1 emergency stop for ACS800-07/17/37 (+Q952, R6i, R7i, n×R8i)
  • Page 81 Category 1 emergency stop for ACS800-07/17/37 (+Q952, R6i, R7i, n×R8i)
  • Page 82 Category 1 emergency stop for ACS800-07/17/37 (+Q952, R6i, R7i, n×R8i)

  • Page 83: Earth Fault Monitoring In It (Ungrounded) Systems (+Q954)

    Earth fault monitoring in IT (ungrounded) systems (+Q954) What this chapter contains This chapter describes earth fault monitoring option +Q954 in IT (ungrounded) systems. The chapter deals with applicability, wiring, operation and use. Example circuit diagrams are included. The chapter also describes the internal earth fault protection of the drive in short.

  • Page 84: Parameter Settings

    AINT Current board Σ I transducers Note concerning parallel-connected inverter modules There is some current deviation between parallel-connected inverter modules due to slight differences in the components. Motor cabling of parallel-connected inverter modules produces cable stray capacitances in a larger scale than in single inverters. When the IGBTs are switched, high-frequency common mode current flows through these stray capacitances to earth.

  • Page 85: Internal Earth Fault Protection Of The Acs800-17/37

    Internal earth fault protection of the ACS800-17/37 The drive is equipped with a similar earth fault protection against earth faults in the motor cable or motor as in the ACS800-07. In addition, the drive is equipped with an earth fault protection against earth faults in the input cable and line-side converter based on input current sum measurement.

  • Page 86: Applicable Standards

    Applicable standards The following standards concern earth fault monitoring in IT systems: • IEC/EN 60204-1:1997 “Safety of machinery – Electrical equipment of machines – Part 1: General requirements”. • IEC 60364-4-41:2001 “Electrical installations of buildings – Protection for satefy – Protection against electrical shock”.
  • Page 87 The monitoring device is connected between the ungrounded system and the drive grounding conductor (PE). The IRDH275 monitors the insulation resistance of the IT system. L1 L2 L3 Transformer Supply unit Inverter units DC busbar BENDER insulation monitoring device Fault current A pulsating AC measuring voltage is superimposed on the system (measuring principle Adaptive Measuring Pulse, developed by BENDER).

  • Page 88: Operation Principle Of The Irdh275

    Operation principle of the IRDH275 The internal structure of the IRDH275 is presented below with a simplified circuit diagram in case of an earth fault in V-phase. Earth fault Bender IRDH275 Earth fault in V-phase When there is no earth fault, the measuring voltage U (direct voltage) does not cause direct current to flow through earth.

  • Page 89: Technical Data

    Technical data Bender insulation monitoring device IRDH275-435 Nominal voltage: 0…793 VAC, 0…650 VDC Resistance response values for Alarm 1 and Alarm 2: 1 kohm …10 Mohm Supply voltage: 88…230 VAC Wiring Typically, the user connects a relay output(s) on the insulation monitoring device to an overriding system.
  • Page 90 This table lists recommended actions in faults indicated by the IRDH275. Display Cause What to do indication No display The alarm relay is in the fault position and the Check the auxiliary power supply of the IRDH275. main contactor / breaker of the drive has opened. Connection PE? Low-resistance conductor to earth is not 1.

  • Page 91: Circuit Diagrams

    Circuit diagrams Example circuit diagrams of the factory wiring are shown below. See the circuit diagrams delivered with the drive for the actual wiring. Earth fault monitoring in IT (ungrounded) systems (+Q954)
  • Page 92 Earth fault monitoring in IT (ungrounded) systems (+Q954)
  • Page 93 Earth fault monitoring in IT (ungrounded) systems (+Q954)
  • Page 94 Earth fault monitoring in IT (ungrounded) systems (+Q954)
  • Page 96 ABB Oy ABB Inc. AC Drives Automation Technologies P.O. Box 184 Drives and Motors FI-00381 HELSINKI 16250 West Glendale Drive FINLAND New Berlin, WI 53151 Telephone +358 10 22 11 +358 10 22 22681 Telephone 262 785-3200 Internet http://www.abb.com 800-HELP-365...

This manual is also suitable for:

Acs800-02Acs800-u2Acs800-07Acs800-u7Acs800-17Acs800-37

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