ACS 600 Hardware Manual This manual includes ACS/ACC/ACP 601 Frequency Converters • Safety 2.2 to 110 kW • Installation • Maintenance (3 to 150 HP) • Product Information ACS 600 ACT PAR FUNC DRIVE ENTER LOC RESET REF REM ACS 600 SingleDrive Manuals GENERAL MANUALS (appropriate hardware manuals is Thyristor Supply Unit (TSU) EN 64170597 included in the delivery) • TSU operation basics • TSU firmware description • TSU program parameters ACS/ACC/ACP 601 Hardware Manual EN 61201360 • TSU commissioning 2.2 to 110 kW • Safety instructions • Cable selection FIRMWARE MANUALS FOR DRIVE APPLICATION • Mechanical and electrical installation PROGRAMS (appropriate manual is included in the • Maintenance delivery) • Technical data • Dimensional drawings Standard EN 61201441 • Control Panel use ACS/ACC/ACP 611 Supplement EN 61504443 • Standard application macros with external control (included in ACx 611 deliveries only) connection diagrams • Safety instructions • Installation • Parameters of the Standard Application Program • Maintenance • Fault tracing • Fault tracing • Fieldbus control Note: a separate Start-up Guide is attached • Parameters • Technical data Motion Control EN 61320130 • Dimensional drawings • Control Panel use • Start-up ACS/ACC/ACP 604/607 Hardware Manual EN 61201394 • Operation 55 to 630 kW • Safety instructions • Parameters • Cable selection • Fault tracing • Mechanical and electrical installation • Fieldbus control • Maintenance Crane Drive EN 3BSE 011179 • Technical data • Commissioning of the Crane Drive Application Program • Dimensional drawings • Control Panel use • Crane program description ACS/ACC 607/627/677 Hardware Manual EN 61329005 • Parameters of the Crane Drive Application Program 630 to 3000 kW • Safety instructions • Fault tracing • Cable selection System EN 63700177 • Mechanical and electrical installation • Commissioning of the System Application Program • Drive section commissioning • Control Panel use • Maintenance • Software description • Technical data • Parameters of the System Application Program • Dimensional drawings • Fault tracing • Terms Converter Module Installation in User-defined Cabinet EN 61264922 (included in modules deliveries only) Application Program Template EN 63700185 • Safety instructions • Commissioning of the Drive Section • Cabinet design • Control Panel use • Wiring • Software description • Installation checks • Parameters • Dimensional drawings • Fault tracing • Terms ACS/ACC 624 Drive Modules Supplement EN 64186477 (included in ACx 624 module deliveries only) • Safety instructions OPTION MANUALS (delivered with optional equipment) • Technical data • Dimensional drawings Fieldbus Adapters, I/O Extension Modules, Braking Choppers etc. SUPPLY UNIT USER’S MANUALS (with 630 to 3000 kW • Installation units depending on the supply type one of these manuals is • Programming included in the delivery) • Fault tracing • Technical data Diode Supply Unit (DSU) EN 61451544 • DSU specific safety instructions • DSU hardware and software descriptions • DSU commissioning • Earth fault protection options ACS/ACC/ACP 601 Frequency Converters 2.2 to 110 kW (3 to 150 HP) Hardware Manual This manual concerns the ACS 601, ACC 601 and ACP 601 frequency converters. In the text, they are collectively referred to as ACx 601. 3AFY 61201360 R0425 REV B EN EFFECTIVE: 6.9.1999 SUPERSEDES: 5.10.1998 ª 1999 ABB Industry Oy. All Rights Reserved. Safety Instructions Overview This chapter states the safety instructions that must be followed when installing, operating and servicing the ACS/ACC/ACP 601. If neglected, physical injury and death may follow, or damage may occur to the frequency converter, the motor and driven equipment. The material in this chapter must be studied before attempting any work on, or with, the unit. The following notation is used throughout the manual: Dangerous Voltage WARNING! warns of situations in which a high voltage can cause physical injury and/or damage equipment. The text next to this symbol describes ways to avoid the danger. General WARNING! warns of situations which can cause physical injury and/or damage equipment by means other than electrical. The text next to this symbol describes ways to avoid the danger. Electrostatic Discharge WARNING! warns of situations in which an electrostatic discharge can damage equipment. The text next to this symbol describes ways to avoid the danger. CAUTION! Aims to draw special attention to a particular issue. Note: Gives additional information or points out more information available on the subject. ACS/ACC/ACP 601 Frequency Converters ACx = ACS/ACC/ACP iii Safety Instructions Installation and(cid:3) These safety instructions are intended for all work on the ACx 601. Maintenance Safety Neglecting these instructions can cause physical injury and death. WARNING! All electrical installation and maintenance work on the ACx 600 should be carried out by qualified electricians. Do not attempt any work on a powered ACx 600. After switching off the mains, always allow the intermediate circuit capacitors 5 minutes to discharge before working on the frequency converter, the motor or the motor cable. The voltage between each input terminal (U1, V1, W1) and earth must be measured with a multimeter (impedance at least 1 MW ) to ensure that the frequency converter is discharged before beginning work. All insulation tests must be carried out with the ACx 600 disconnected from the cabling. The ACx 600 motor cable terminals are at a dangerously high voltage when input power is applied, regardless of motor operation. No work on the motor cable should be attempted with mains power applied. The brake control terminals (UDC+, UDC-, R+ and R- terminals) carry a dangerous DC voltage (over 500 V). There can be dangerous voltages inside the ACx 600 from external control circuits when the ACx 600 input power is shut off. No work on the control cables should be attempted when power is applied to the frequency converter or to the external control circuits. Exercise appropriate care when working with the unit. Supply Connections For ACx 601 a supply disconnecting device must be installed in the supply, by which the electric parts of the unit can be separated from the mains network during installation and maintenance work. The supply disconnecting device must be locked to the open position during installation and maintenance work. To meet the European Union Directives the isolator must be of a load switch type according to EN 60947-3 Class B or of a type that switches off the loaded circuit by means of an auxiliary contact opening the main contacts of a switch. iv ACx = ACS/ACCACP ACS/ACC/ACP 601 Frequency Converters Safety Instructions If an ACx 601 with the integrated EMC filter (code 0 in the type code for EMC Filters) is installed to unearthed mains (an ungrounded power system or a high resistance grounded power system (over 30 ohms)), the mains will be connected to earth potential through the EMC filter capacitors of the ACx 601. This may cause danger or damage the unit. Disconnect the EMC filter capacitors before connecting the ACx 601 to unearthed mains. For detailed instructions on how to do this, please contact your local ABB distributor. The motor must not be controlled with the supply disconnecting device; instead, the and keys of the Control Panel or commands via the I/O board of the ACx 600 should be used. The maximum number of charging cycles of the d.c. capacitors of ACx 600 (i.e. power-ups by applying the mains power) is five in ten minutes. WARNING! Never connect the mains (line power) to the ACx 600 output. If frequent bypassing is required, mechanically connected switches or contactors should be employed. Mains (line) voltage applied to the output can result in permanent damage to the unit. Operation outside the nominal voltage range should not be attempted, as overvoltages can result in permanent damage to the ACx 600. Earth (Ground) Fault The ACx 600 is equipped with an internal earth fault protective function Protective Function to protect the unit against earth faults in the inverter, the motor and the motor cable. This is not a personal safety or a fire protection feature. The earth fault protective function of the ACS/ACP 600 can be disabled by Parameter 30.17 (ACC: 30.11). The EMC filter of the ACx 600 includes capacitors connected between the main circuit and the frame. These capacitors increase the earth (ground) leakage current through the PE connector to the mains (line) and may cause some fault current circuit breakers to function. Emergency Stop Emergency stop devices must be installed at each operator control Devices station and at other operating stations where emergency stop may be required. Pressing the key on the Control Panel of ACx 600 does not generate an emergency stop of the motor or separate the drive from dangerous potential. ACS/ACC/ACP 601 Frequency Converters ACx = ACS/ACC/ACP v Safety Instructions Motor Connections WARNING! Operation is not allowed if the motor nominal voltage is less than one half of (ACP: 0.4 times) the ACx 600 nominal input voltage, or the motor nominal current is less than 1/6 of the ACx 600 nominal output current. As with all frequency converters employing the most modern IGBT inverter technology, the ACx 600 output comprises – regardless of output frequency – pulses of approximately 1.35 times the mains network voltage with a very short rise time. The voltage of the pulses can be almost double at the motor terminals, depending on the motor cable properties. This in turn can cause additional stress to the motor insulation. The motor manufacturer should be consulted regarding the construction of the motor insulation. Failure of the motor to fulfil the following requirements may shorten its life. Motor Insulation The requirement of motor insulation level in ACx 600 frequency Requirement converter drive is given below. Motor Type Nominal Mains Voltage Motor Insulation Requirement ABB M2_ Motors with UN < 500 V 6WDQGDUG(cid:3)LQVXODWLRQ(cid:3)V\VWHP IEC Frame 500 V < UN £ 600 V 6WDQGDUG(cid:3)LQVXODWLRQ(cid:3)DQG(cid:3)GX(cid:18)GW(cid:3)ILOWHU RU UHLQIRUFHG(cid:3)LQVXODWLRQ(cid:3)V\VWHP 600 V < UN £ 690 V 5HLQIRUFHG(cid:3)LQVXODWLRQ(cid:3)V\VWHP(cid:3)DQG(cid:3)GX(cid:18)GW(cid:3) ILOWHU ABB M2_ Motors with 460 V < UN < 600 V 5HLQIRUFHG(cid:3)LQVXODWLRQ(cid:3)V\VWHP NEMA Frame 5DQGRP(cid:16)ZRXQG(cid:3)0RWRUV UN £ 420 V 0RWRU(cid:3)LQVXODWLRQ(cid:3)V\VWHP(cid:3)PXVW(cid:3)ZLWKVWDQG(cid:3) (cid:211)LL= 1300 V. 420 V < UN £ 500 V ,I(cid:3)PRWRU(cid:3)LQVXODWLRQ(cid:3)V\VWHP(cid:3)ZLWKVWDQGV(cid:3) (cid:211)LL= 1600 V(cid:3)DQG(cid:3)(cid:19)(cid:17)(cid:21)(cid:3)m V(cid:3)ULVH(cid:3)WLPH(cid:15)(cid:3)D(cid:3) du/dt filter(cid:3)LV(cid:3)QRW(cid:3)QHHGHG(cid:17)(cid:3) With a du/dt filter at the output of the ACx 600, PRWRU(cid:3)LQVXODWLRQ(cid:3)V\VWHP(cid:3)must(cid:3) ZLWKVWDQG(cid:3)(cid:211)LL= 1300 V. 500 V < UN £ 600 V 0RWRU(cid:3)LQVXODWLRQ(cid:3)V\VWHP(cid:3)PXVW(cid:3)ZLWKVWDQG(cid:3) (cid:211)//(cid:3) (cid:3)(cid:20)(cid:25)(cid:19)(cid:19)(cid:3)9(cid:17)(cid:3)$(cid:3)GX(cid:18)GW(cid:3)ILOWHU(cid:3)PXVW(cid:3)EH(cid:3) XVHG(cid:3)DW(cid:3)WKH(cid:3)RXWSXW(cid:3)RI(cid:3)WKH(cid:3)$&[(cid:3)(cid:25)(cid:19)(cid:19)(cid:17) 600 V < UN £ 690 V 0RWRU(cid:3)LQVXODWLRQ(cid:3)V\VWHP(cid:3)PXVW(cid:3)ZLWKVWDQG(cid:3) (cid:211)LL= 1800 V. A du/dt filter must be used DW(cid:3)WKH(cid:3)RXWSXW(cid:3)RI(cid:3)WKH(cid:3)$&[(cid:3)(cid:25)(cid:19)(cid:19). )RUP(cid:16)ZRXQG(cid:3)0RWRUV UN £ 690 V ,I(cid:3)PRWRU(cid:3)LQVXODWLRQ(cid:3)V\VWHP(cid:3)ZLWKVWDQGV(cid:3) m (cid:211)// (cid:3)(cid:21)(cid:19)(cid:19)(cid:19)(cid:3)9(cid:3)DQG(cid:3)ULVH(cid:3)WLPH(cid:19)(cid:17)(cid:22)(cid:3) V(cid:15)(cid:3)QR(cid:3) GX(cid:18)GW(cid:3)ILOWHU(cid:3)LV(cid:3)QHHGHG(cid:17) vi ACx = ACS/ACCACP ACS/ACC/ACP 601 Frequency Converters Safety Instructions Symbol Definition U nominal mains voltage N (cid:211)LL peak line to line voltage at motor terminals Rise time: Rise time is line to line voltage change rate at motor terminals (the interval during which the voltage changes from 10 % to 90% of the whole voltage range) t = 0.8 · (cid:211)LL/(du/dt) ÛLL and t depend on cable length. RHDG(cid:3) WKH(cid:3)YDOXHV(cid:3)RI(cid:3)(cid:211)LL and du/dt from the diagrams below. Without Filtering Below is a diagram of and du/dt as a function of cable length when (cid:211)LL no du/dt filter is used. 4 3.5 3 (cid:211)LL/ UN 2.5 2 du/dt / (kV/m s) 1.5 1 0.5 0 0 100 200 300 400 Cable length (m) With du/dt Filter Below is a diagram of and du/dt as a function of cable length with (cid:211)LL du/dt filter at the output of the ACx 600. 4 3.5 3 2.5 (cid:211)LL/ UN 2 1.5 1 du/dt / (kV/m s) 0.5 0 0 100 200 300 400 Cable length (m) ACS/ACC/ACP 601 Frequency Converters ACx = ACS/ACC/ACP vii Safety Instructions WARNING! The ACx 600 introduces electric motors, drive train mechanisms and driven machines to an extended operating range. It should be determined from the outset that all equipment is up to these conditions. WARNING! There are several automatic reset functions in the ACS 600 (with Standard Application Program). If selected, they reset the unit and resume operation after a fault. These functions should not be selected if other equipment is not compatible with this kind of operation, or dangerous situations can be caused by such action. WARNING! If an external source for start command is selected and it is ON, the ACS 600 (with Standard Application Program) will start immediately after fault reset. Power Factor Power factor compensation capacitors and surge absorbers must not Compensation be connected to the motor cables. These devices are not designed to Capacitors be used with frequency converters, and will degrade motor control accuracy. They can cause permanent damage to the ACx 600 or themselves due to the rapid changes in the ACx 600 output voltage. If there are power factor compensation capacitors in parallel with the ACx 600 make sure that the capacitors and the ACx 600 are not charged simultaneously to avoid voltage surges which might damage the unit. Output Contactors If a contactor is used between the output of the ACx 600 and the motor with DTC control mode selected, the output voltage of the ACx 600 must be controlled to zero before the contactor is opened: ACS 600 units via parameter 21.3 (ACP: 10.4), choose COAST. If RAMP is selected, the output of the ACS/ACP 600 must be reduced to zero using Parameter 16.1 by giving zero V DC to the selected digital input. Otherwise the contactor will be damaged. In scalar control the contactor can be opened with ACS/ACC 600 running. Varistors or RC networks (AC) or diodes (DC) should be used to protect against voltage transients generated by contactor coils. The protective components should be mounted as close as possible to the contactor coils. Protective components should not be installed at the NIOC board terminal block. viii ACx = ACS/ACCACP ACS/ACC/ACP 601 Frequency Converters