ABB ACS800-U7 User Manual

Safety instructions
9
Operation
These warnings are intended for all who plan the operation of the drive or operate
the drive.
WARNING! Ignoring the 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 (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.
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 .

ABB ACS800-U7 Specifications

General

Brand	ABB
Model	ACS800-U7
Category	DC Drives
Language	English

Summary

Hardware Manual

Safety instructions

Use of warnings and notes

Installation and maintenance work

Safety warnings and instructions for installing and maintaining the drive.

Grounding

Instructions and warnings for proper grounding of the drive and equipment.

Mechanical installation and maintenance

Safety warnings for mechanical installation and maintenance procedures.

Printed circuit boards

Fibre optic cables

Operation

Safety warnings and instructions for operating the drive.

Operation principle and hardware description

Type designation key

Mechanical installation

Moving the unit

Delivery check

Requirements for the installation site

Cooling air flow

Fastening the cabinet to the floor and wall (non-marine units)

Instructions for fastening the cabinet to the floor and wall.

Fastening the cabinet with the outside brackets

Details on how to fasten the cabinet using outside brackets.

Fastening the cabinet through the holes inside the cabinet

Instructions for fastening the cabinet using internal cabinet holes.

Fastening the cabinet to the floor and roof/wall (marine units)

Instructions for fastening marine units to floor/roof/wall.

Planning the electrical installation

Motor selection and compatibility

Guidance on selecting compatible motors for the drive system.

Motor voltage rating requirements

Requirements for motor voltage rating to ensure compatibility with the drive.

Protecting the motor insulation and bearings

Methods to protect motor insulation and bearings from drive output.

Requirements table

Table detailing motor insulation and filter requirements based on motor type.

Non-ABB motors requirements

Requirements for motor insulation and filters for non-ABB motors.

Additional requirements for explosion-safe (EX) motors

Additional requirements for using explosion-safe (EX) motors.

Additional requirements for ABB high-output and IP23 motors

Specific requirements for ABB high-output and IP23 motors.

Additional requirements for non-ABB high-output and IP23 motors

Requirements for non-ABB high-output and IP23 motors.

Additional data for calculating the rise time and the peak line-to-line voltage

Permanent magnet synchronous motor

Guidance for connecting permanent magnet synchronous motors.

Supply connection

Thermal overload and short-circuit protection

Details on thermal overload and short-circuit protection for drive and cables.

Thermal overload protection of the motor

Explanation of the drive's motor thermal protection function.

Protection against short-circuit in the motor cable

How the drive protects the motor cable against short circuits.

Protection against short-circuit inside the drive or in the supply cable

Guidance on protecting against short circuits within the drive or supply cable.

Ground fault protection

Explanation of the drive's internal ground fault protection function.

Emergency stop devices

Instructions for installing and using emergency stop devices.

Restarting after an emergency stop

Prevention of unexpected start-up

Details on the optional Prevention of Unexpected Start-up (POUS) function.

Safe torque off (STO)

Explanation of the Safe Torque Off (STO) function for safety.

Selecting the power cables

Guidelines for selecting appropriate power cables for the drive.

General rules

General rules for dimensioning and selecting power cables.

Alternative power cable types

Motor cable shield

Equipment connected to the motor cable

Bypass connection

Before opening a contactor (DTC control mode selected)

Protecting the relay output contacts and attenuating disturbances in case of inductive loads

Selecting the control cables

Guidelines for selecting appropriate control cables.

Connection of a motor temperature sensor to the drive I/O

Installation sites above 2000 metres (6562 feet)

Routing the cables

Electrical installation

IT (ungrounded) systems

Checking the insulation of the assembly

Procedures for checking drive, input cable, and motor cable insulation.

Drive

Do not perform insulation tests on the drive; factory tested.

Input cable

Motor and motor cable

Check motor cable disconnection and measure insulation resistance.

Brake resistor assembly

Grounding of the motor cable shield at the motor end

Connecting the power cables

Step-by-step instructions for connecting power cables to the drive.

Additional instructions for frame size R6

Cable lug installations to R+ and R- screws

Connecting the control cables

Instructions for connecting control cables.

Routing the cables (frame sizes R5 and R6)

Routing the cables (frame sizes R7 and R8)

360 degrees EMC grounding at the cable entry

Procedure for achieving 360-degree EMC grounding at cable entry.

Connecting the cables to the I/O terminals

Installation of brake resistors (units with brake chopper option)

Motor control and I/O board (RMIO)

Note on external power supply

External control connections (non-US)

External control connections (US)

RMIO board specifications

Installation checklist and start-up

Checklist

Checklist for mechanical and electrical installation before drive start-up.

Start-up procedure

Steps and checks for the drive start-up procedure.

Checks with no voltage connected

Checks to perform with no voltage connected before start-up.

Starting the drive

How to start the drive by closing the main disconnector.

Control program set-up

Instructions for setting up the control program and drive parameters.

On-load checks

Checks to perform after the drive is running under load.

Maintenance

Safety

Safety warnings to follow before performing any maintenance.

Maintenance intervals

Recommended routine maintenance intervals for the drive.

Checking and replacing the air filters

How to check and replace air filters for the drive.

Heatsink

Fans

Replacing the drive module fan (R5 and R6)

Step-by-step instructions for replacing drive module fans in R5 and R6.

Replacing the drive module fan (R7)

Step-by-step instructions for replacing drive module fans in R7.

Replacing the drive module fan (R8)

Step-by-step instructions for replacing drive module fans in R8.

Replacing the cabinet fans (R5 and R6)

Instructions for replacing cabinet fans in R5 and R6.

Replacing the additional fan at the lower part of the cubicle (R6 with du/dt filter, +E205)

Replacing the cabinet fans (frame size R8 only)

Instructions for replacing cabinet fans in frame size R8.

Replacing the additional cabinet fan (frame sizes R7 and R8 only with IP22 and IP42 when cabling: bottom entry/exit)

Replacing the additional cabinet fan (frame sizes R7 and R8 only with IP22 and IP42 when cabling: top entry and bottom exit, bottom entry and top exit or top entry/exit)

Replacing the IP54 (UL type 12) fan in frame size R6 (option +B055 and +B059)

Replacing the IP54 (UL type 12) fan in frame sizes R7 and R8 (option +B055 and +B059)

Capacitors

Replacing the capacitor pack (R7)

Instructions for replacing the capacitor pack in frame size R7.

Replacing the capacitor pack (R8)

Replacing the drive module (R5 and R6)

Step-by-step instructions for replacing the drive module in R5 and R6.

Replacing the drive module (R7 and R8)

Step-by-step instructions for replacing the drive module in R7 and R8.

Technical data

IEC data

Ratings

IEC ratings for ACS800-07 drives at 50 Hz and 60 Hz supplies.

Symbols

Sizing

Derating

Fuses

Information on standard and optional fuses for short-circuit protection.

Ultrarapid (aR) fuses

Optional gG fuses

Quick guide for selecting between gG and aR fuses

A quick guide for selecting between gG and aR fuses based on cable and transformer parameters.

Cable types

Cable entries

NEMA data

UL class T or L fuses

Input power connection

Voltage, current, frequency, and imbalance specifications for input power.

Motor connection

Voltage, frequency, current, power limit, and cable length for motor connection.

Cooling

Ambient conditions

Applicable standards

CE marking

Compliance with the European Low Voltage Directive

Compliance with the EMC Directive

Compliance with EN 61800-3:2004

Second environment (drive of category C3)

Second environment (drive of category C4)

Machinery Directive

“C-tick” marking

UL/CSA markings

Resistor braking

Availability of brake choppers and resistors

How to select the correct drive/chopper/resistor combination

Steps for selecting the correct drive, chopper, and resistor combination.

Optional brake chopper and resistor(s)

Table showing nominal ratings for brake resistors and choppers.

Combined braking cycles for R7

Combined braking cycles for R8

Resistor installation and wiring

Instructions for installing and wiring brake resistors.

Protection of frame size R5

Protection of frame sizes R6, R7 and R8

Brake circuit commissioning

Steps for commissioning the brake circuit for Standard Control Program.