Hardware Manual ACS800-04 and ACS800-04M Drive Modules (45 To 560 KW) ACS800-U4 Drive Modules (60 To 600 HP)

ACS800
Hardware Manual ACS800-04 and ACS800-04M Drive Modules (45 to 560 kW) ACS800-U4 Drive Modules (60 to 600 HP)
ACS800 Single Drive Manuals

HARDWARE MANUALS (appropriate manual is included in the delivery) ACS800-01/U1 Hardware Manual 0.55 to 160 kW (0.75 to 200 HP) 3AFE64382101 (English) ACS800-01/U1/04 Marine Supplement 0.55 to 160 kW (0.75 to 200 HP) 3AFE64291275 (English) ACS800-11/U11 Hardware Manual 5.5 to 110 kW (7.5 to 125 HP) 3AFE68367883 (English) ACS800-31/U31 Hardware Manual 5.5 to110 kW (7.5 to 125 HP) 3AFE68599954 (English) ACS800-02/U2 Hardware Manual 90 to 500 kW (125 to 600 HP) 3AFE64567373 (English) ACS800-04/U4 Hardware Manual 0.55 to 160 kW (0.75 to 200 HP) 3AFE68372984 (English) ACS800-04/04M/U4 Hardware Manual 45 to 560 kW (60 to 600 HP) 3AFE64671006 (English) ACS800-04/04M/U4 Cabinet Installation 45 to 560 kW (60 to 600 HP) 3AFE68360323 (English) ACS800-07/U7 Hardware Manual 45 to 560 kW (50 to 600 HP) 3AFE64702165 (English) ACS800-07/U7 Dimensional Drawings 45 to 560 kW (50 to 600 HP) 3AFE64775421 ACS800-07 Hardware Manual 500 to 2800 kW 3AFE64731165 (English) ACS800-17 Hardware Manual 55 to 2500 kW (75 to 2800 HP) 3AFE68397260 (English) ACS800-37 Hardware Manual 55 to 2700 kW (75 to 3000 HP) 3AFE68557925 (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 Control Program Firmware Manual 3AFE64527592 (English) System Control Program Firmware Manual 3AFE64670646 (English) Control Program Template Firmware Manual 3AFE64616340 (English) Master/Follower 3AFE64590430 (English) Pump Control Program Firmware Manual 3AFE68478952 (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.
ACS800-04 and ACS800-04M Drive Modules 45 to 560 kW ACS800-U4 Drive Modules 60 to 600 HP Hardware Manual
3AFE64671006 Rev F EN EFFECTIVE: 15.6.2007
2007 ABB Oy. All Rights Reserved.
Update Notice
The notice concerns the following ACS800-04 and ACS800-04M Drive Modules (45 to 560 kW) and ACS800-U4 Drive Modules (60 to 600 HP) Hardware Manuals: Code 3AFE64671006 3AFE68242193 3AFE68367000 3AFE68367018 3AFE68243432 Revision F F F F F Language English German Spanish French Italian EN DE ES FR IT Code: 3AUA0000068945 Rev A Valid: from 01.02.2010 until the release of the next revision of the manual Contents: The headings in this update notice refer to the modified subsections in the original English manual. Each heading also includes a page number and a classifier NEW, CHANGED, or DELETED. The page number refers to the page number in the original English manual. The classifier describes the type of the modification.
NEW (page 6): Safety / Installation and maintenance work

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 Safe torque off function (option +Q967) does not remove the voltage from the main and auxiliary circuits.
CHANGED (page 11): Safety / Permanent magnet 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.
CHANGED (page 23): The ACS800-04/U4

Terminal block for user connection of optional Prevention of unexpected start (+Q950) or optional Safe torque off (+Q967).
Update Notice
NEW (pages 26-27): Type code

The table below contains the new option code definition for the Safe torque off function.
Code +Q967 Description Safe torque off (STO)
NEW (page 43): Emergency stop

Note: If you add or modify the wiring in the drive safety circuits, ensure that the appropriate standards (e.g. IEC 61800-5-1, EN 62061, EN/ISO 13849-1 and -2) and the ABB guidelines are met. After making the changes, verify the operation of the safety function by testing it.
NEW (page 46): Safe torque off

The drive supports the Safe torque off (STO) function according to standards EN 61800-5-2:2007; EN/ISO 13849-1:2008, IEC 61508, and EN 62061:2005. The function also corresponds to an uncontrolled stop in accordance with category 0 of EN 60204-1 and prevention of unexpected start-up of EN 1037. The STO may be used where power removal is required to prevent an unexpected start. The function disables the control voltage of the power semiconductors of the drive output stage, thus preventing the inverter from generating the voltage required to rotate the motor (see the diagram below). By using this function, short-time operations (like cleaning) and/or maintenance work on non-electrical parts of the machinery can be performed without switching off the power supply to the drive.
Update Notice
Update Notice
WARNING! The Safe torque off function does not disconnect the voltage of the main and auxiliary circuits from the drive. Therefore maintenance work on electrical parts of the drive or the motor can only be carried out after isolating the drive system from the main supply. Note: The Safe torque off function can be used for stopping the drive in emergency stop situations. In the normal operating mode, use the Stop command instead. If a running drive is stopped by using the function, the drive will trip and stop by coasting. If this is not acceptable, e.g. causes danger, the drive and machinery must be stopped using the appropriate stopping mode before using this function. Note concerning permanent magnet motor drives in case of a multiple IGBT power semiconductor failure: In spite of the activation of the Safe torque off function, the drive system can produce an alignment torque which maximally rotates the motor shaft by 180/p degrees. p denotes the pole pair number. Note: If you add or modify the wiring in the drive safety circuits, ensure that the appropriate standards (e.g. IEC 61800-5-1, EN 62061, EN/ISO 13849-1 and -2) and the ABB guidelines are met. After making the changes, verify the operation of the safety function by testing it.
Update Notice
CHANGED (page 82): LEDs

LED V309 (red) Indication Prevention of unexpected start (option +Q950) or Safe torque off (option +Q967) is ON.
NEW (page 100): Safe torque off (+Q967): ASTO-21 board

Nominal input voltage Nominal input current X1 terminal sizes Nominal output current X2 terminal block type Ambient temperature Relative humidity Dimensions (with enclosure) Weight (with enclosure) 24 V DC 40 mA (20mA per channel) 4 x 2.5 mm2 0.4 A JST B4P-VH 0...50C Max. 90%, no condensation allowed 167 x 128 x 52 mm (Height x Weight x Depth) 0.75 kg
NEW (page 100): Ambient conditions

Modules with option +Q967: the installation site altitude in operation is 0 to 2000 m.
Operation installed for stationary use Installation site altitude
[...]
Modules with option +Q967: 0 to 2000 m
Update Notice
Update Notice
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.
To which products this chapter applies

This chapter applies to the ACS800-01/U1, ACS800-11/U11, ACS800-31/U31, ACS800-02/U2 and ACS800-04/04M/U4 of frame sizes R7 and R8.
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
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 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 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, ACS800-01/U1, ACS800-04/ 04M, ACS800-11/U11, ACS800-31/U31). ACS800-02 with enclosure extension: The main switch on the cabinet door does not remove the voltage from the input busbars of the drive. Before working on the drive, isolate the whole drive from the supply. ACS800-01/U1, ACS800-04/04M, ACS800-11/U11, ACS800-31/U31: The Prevention of Unexpected Start function does not remove the voltage from the main and auxiliary circuits.
Safety instructions
At installation sites above 2000 m (6562 ft), the terminals of the RMIO board and optional modules attached to the board do not fulfil the Protective Extra Low Voltage (PELV) requirements stated in EN 50178.
Grounding These instructions are intended for all who are responsible for the grounding of the drive. 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). ACS800-01, ACS800-11, ACS800-31: 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. ACS800-04 (45 to 560 kW) and ACS800-02 in first environment: make a 360 high frequency grounding of motor cable entries at the cabinet lead-through.
Do not install a drive with EMC filter option +E202 or +E200 (available for ACS800-01 and ACS800-11, ACS800-31 only) 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.
Safety instructions
Mechanical installation and maintenance These instructions are intended for all who install and service the drive. WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment:
Handle the unit carefully. ACS800-01, ACS800-11, ACS800-31: 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. ACS800-02, ACS800-04: The drive is heavy. Lift the drive by the lifting lugs only. Do not tilt the unit. The unit will overturn from a tilt of about 6 degrees. Use extreme caution when manoeuvring a drive that runs on wheels. An overturning unit can cause physical injury.
Do not tilt!
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.
Safety instructions
Printed circuit boards 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.
Fibre optic cables 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
10
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 (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 .
Safety instructions
11
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. 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 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 or output terminals (U1, V1, W1, U2, V2, W2, UDC+, UDC-). Alternative 2) Measure that there is no voltage present on the drive input or output 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 may damage or explode the capacitors in the intermediate circuit of the drive. Controlling a permanent magnet motor is only allowed using the control program for Permanent Magnet Synchronous Machine Drive, or other control programs in scalar control mode.
Safety instructions
12
Safety instructions
13
Table of contents
ACS800 Single Drive Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety instructions What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 To which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Mechanical installation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Fibre optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Permanent magnet motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Start-up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Table of contents About this manual What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Common chapters for several products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Categorization according to the frame size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Categorization according to the plus code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Other related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation, commissioning and operating flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The ACS800-04/U4 and ACS800-04M What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The ACS800-04/U4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The ACS800-04M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Example configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 23 24 24 25 26 19 19 19 19 19 20 20 20 21 21 22
Table of contents
14
Control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Connections of the Drive Control Unit (RDCU) in frame sizes R7 and R8 . . . . . . . . . . . . . . .29 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Mechanical installation What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Requirements for the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Cooling air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Cable channel in the floor below the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Fastening the cabinet to the floor and wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Electric welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Planning the electrical installation What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 To which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Motor selection and compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35 Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 Permanent magnet synchronous motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Supply connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Disconnecting device (disconnecting means) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 ACS800-01, ACS800-U1, ACS800-11, ACS800-U11, ACS800-31, ACS800-U31, ACS800-02 and ACS800-U2 without enclosure extension, ACS800-04, ACS800-U4 .40 ACS800-02 and ACS800-U2 with enclosure extension, ACS800-07 and ACS800-U7 .40 EU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 US . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Main contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40 Thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Thermal overload protection of the drive and the input and motor cables . . . . . . . . . . . . . . .41 Thermal overload protection of the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Protection against short-circuit in the motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Protection against short-circuit inside the drive or in the supply cable . . . . . . . . . . . . . . . . . .42 Ground fault protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Emergency stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 ACS800-02/U2 with enclosure extension and ACS800-07/U7 . . . . . . . . . . . . . . . . . . . . . . . .43 Restarting after an emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Power-loss ride-through function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 ACS800-07/U7 units without line contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 ACS800-07/U7 units with line contactor (+F250) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Prevention of Unexpected Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
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Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power factor compensation capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment connected to the motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of safety switches, contactors, connection boxes, etc. . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connection of a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation sites above 2000 metres (6562 feet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical installation What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Input cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of optional EMC filter (+E202) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Example wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power cable connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Grounding of the cable shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fastening US cable lugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Example mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connections of the RDCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting the control cables to the RMIO board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting the shield wires at RMIO board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Securing the control cables mechanically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Settings of the cooling fan transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation of optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cabling of I/O and fieldbus modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pulse encoder module cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fibre optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46 46 47 47 48 48 48 48 49 49 49 49 50 51 51 51 52 52 52 53
55 55 55 55 55 55 56 56 57 58 59 60 60 61 62 62 62 63 63 63 64 64 64
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Motor control and I/O board (RMIO) What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 To which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Note for the ACS800-02 with enclosure extension and the ACS800-07 . . . . . . . . . . . . . . . . . . . . .65 Note on terminal labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Note on external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 Parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 External control connections (non-US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 External control connections (US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 RMIO board specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Analogue inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Constant voltage output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Auxiliary power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Analogue outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 DDCS fibre optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 24 VDC power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 Maintenance What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73 Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74 Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Replacing the fan (R7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 Replacing the fan (R8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Replacing the capacitor pack (R7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Replacing the capacitor pack (R8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 Replacing the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
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Technical data What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 IEC data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Calculation example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Fuse tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 gG fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Ultrarapid (aR) fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Quick guide for selecting between gG and aR fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Cable entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Dimensions, weights and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 NEMA data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 UL class T and L fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Cable Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Dimensions, weights and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Input power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Prevention of Unexpected Start: AGPS-21 board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 US patents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Compliance with the EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Compliance with the EN 61800-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 First environment (drive of category C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Second environment (drive of category C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Second environment (drive of category C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
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18
C-tick marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 Compliance with IEC 61800-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 First environment (drive of category C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 Second environment (drive of category C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105 Second environment (drive of category C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105 UL/CSA markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 UL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 Equipment warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 Resistor braking What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 To which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 Availability of brake choppers and resistors for the ACS800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 How to select the correct drive/chopper/resistor combination . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 Optional brake chopper and resistor(s) for the ACS800-01/U1 . . . . . . . . . . . . . . . . . . . . . . . . . . .108 Optional brake chopper and resistor(s) for the ACS800-02/U2, ACS800-04/04M/U4 and ACS800-07/U7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 Resistor installation and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113 ACS800-07/U7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114 Protection of frame sizes R2 to R5 (ACS800-01/U1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114 Protection of frame size R6 (ACS800-01, ACS800-07) and frame sizes R7 and R8 (ACS800-02, ACS800-04, ACS800-07) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114 Brake circuit commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
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19
About this manual

This chapter describes the intended audience and contents of the manual. It contains a flowchart of steps in checking the delivery, installing and commissioning the drive. The flowchart refers to chapters/sections in this manual and other manuals.
Target audience
This manual is intended for people who plan the electrical installation, install, commission, use and service the drive. Read the manual before working on the drive. The reader is expected to know the fundamentals of electricity, wiring, electrical components and electrical schematic symbols. The manual is written for readers worldwide. Both SI and imperial units are shown. Special US instructions for installations within the United States that must be installed per the National Electrical Code and local codes are marked with (US).
Common chapters for several products

Chapters Planning the electrical installation, Motor control and I/O board (RMIO) and Resistor braking apply to the ACS800-01/U1, ACS800-02/U2, ACS800-04/04M/U4 and ACS800-07/U7 types up to -0610-x. Safety instructions apply to the ACS800-01/ U1, ACS800-02/U2 and ACS800-04/04M/U4.
Categorization according to the frame size

The instructions, technical data and dimensional drawings which concern only certain frame sizes are marked with the symbol of the frame size R2, R3... or R8. The frame size is not marked on the drive designation label. To identify the frame size of your drive, see rating tables in chapter Technical data.
Categorization according to the plus code

The instructions, technical data and dimensional drawings which concern only certain optional selections are marked with plus codes, e.g. +E210 or +H354. The options included in the drive can be identified from the plus codes visible on the type designation label of the drive. The plus code selections are listed in chapter The ACS800-04/U4 and ACS800-04M under Type code.
About this manual
20
Contents
The chapters of this manual are briefly described below. Safety instructions give safety instructions for the installation, commissioning, operation and maintenance of the drive. About this manual introduces this manual. The ACS800-04/U4 and ACS800-04M describes the drive. Mechanical installation describes the mechanical installation of the drive cabinet generally. Planning the electrical installation instructs on the motor and cable selection, protections and cable routing. Electrical installation instructs how to wire the drive. Motor control and I/O board (RMIO) shows external control connections and specifications of the motor control and I/O board. Maintenance contains preventive maintenance instructions. Technical data contains the technical specifications of the drive, e.g. the ratings, sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings and warranty policy. Resistor braking describes how to select, protect and wire optional brake choppers and resistors. The chapter also contains technical data.
Other related manuals

Refer to ACS800-04/04M/U4 Cabinet Installation [3AFE68360323 (English)] for information concerning the drive module such as dimensional drawings of the drive module installing the drive module into a cabinet.
Installation, commissioning and operating flowchart

Task Identify the frame size of your drive, R7 or R8. See Technical data / IEC data or NEMA data
Plan the installation.
Technical data
Check the ambient conditions, ratings, required Planning the electrical installation cooling air flow, input power connection, compatibility Option manual (if optional equipment is of the motor, motor connection, and other technical included) data. Select the cables.
About this manual
21
Task Unpack and check the units. Check that all necessary optional modules and equipment are present and correct. Only intact units may be started up.
See If the converter has been non-operational for more than one year, the converter DC link capacitors need to be reformed. Ask ABB for instructions.
Check the installation site.
Technical data
If the drive is about to be connected to an IT (ungrounded) system, check that the drive is not equipped with EMC filter +E202.
The ACS800-04/U4 and ACS800-04M: Type code. For instructions on how to disconnect the EMC filtering, contact ABB.
Route the cables.
Planning the electrical installation: Routing the cables
Check the insulation of the motor and the motor cable.
Electrical installation: Checking the insulation of the assembly
Install the drive. Connect the power cables. Connect the control and the auxiliary control cables.
Electrical installation, Resistor braking (optional)
Commission the drive.
Appropriate firmware manual
Commission the optional brake chopper (if present).
Resistor braking
Operating of the drive: start, stop, speed control etc.
Appropriate firmware manual
Product and service inquiries

Address any inquiries about the product to your local ABB representative, quoting the type code and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/drives and selecting Drives Sales, Support and Service network on the right pane.
Product training
For information on ABB product training, navigate to www.abb.com/drives and select Drives Training courses on the right pane.
About this manual
22
Providing feedback on ABB Drives manuals

Your comments on our manuals are welcome. Go to www.abb.com/drives, then select successively Drives Document Library Manuals feedback form on the right pane.
About this manual
23
The ACS800-04/U4 and ACS800-04M

This chapter describes the construction and operating principle of the drive in short.
The ACS800-04/U4
The ACS800-04/U4 is an IP 00 drive module for controlling AC motors. It is to be installed into a cabinet by the customer with base or wall fastening. The input cable terminals are located at the top of the unit whereas the motor cable terminals are located at the left- or right-hand side of the unit. The unit is delivered pre-assembled with mounting pedestal and output busbars.
Slots for cables going to the RMIO board in the RDCU unit. The cables are coiled on the top of the module. Fastening points Input cable terminals Fastening points Terminal block for user connection of optional Prevention of Unexpected Start (+Q950). See ACS800-04/04M/U4 Cabinet Installation [3AFE68360323 (English)] chapter Circuit diagrams. Fastening points
Front cover Motor cable terminals Optional brake and DC busbars and terminals
Drive Control Unit (RDCU)
PE terminal
Additional holes for fastening the cable terminals
Alternative output cable terminals (when no vertical busbars are used)
Pedestal
Fastening bracket
24
The ACS800-04M
The ACS800-04M is delivered as non-pre-assembled kits, which provide more alternatives in assembling the units than the basic ACS800-04. Example configurations
Frame size R7
Motor and brake busbars on the left-hand long side of the module and DC busbars on the right-hand side
Motor and brake busbars on the right-hand long side of the module and DC busbars on the left-hand side
Output busbars on the short side of the module
Frame size R8 Drive Control Unit (RDCU)
Frame size R7 with bottom exit (optional top entry busbar shroud and bottom exit shroud included). Output busbars are located at the base of the module. Output busbars on the short side of the module
25
Type designation label

The type designation label includes an IEC and NEMA rating, C-UL US, and CSA markings, a type code and a serial number, which allow individual recognition of each unit. The first digit of the serial number refers to the manufacturing plant. The next four digits refer to the units manufacturing year and week respectively. The remaining digits complete the serial number so that there are no two units with the same serial number. The type designation label is located on the front cover and the serial number label inside the unit. Example labels are shown below.
26
Type code
The type code contains information on the specifications and configuration of the drive. The first digits from left express the basic configuration (e.g. ACS800-040170-5). The optional selections are given thereafter, separated by plus signs (e.g. +E202). The main selections are described below. Not all selections are available for all types. For more information, refer to ACS800 Ordering Information (EN code: 64556568, available on request).
Type code for ACS800-04 and ACS800-U4 pre-assembled units Alternatives ACS800 product series 04 Drive module. When no options are selected: 6-pulse diode input bridge, IP 00, top entry, side exit, RDCU drive control unit, no control panel, no EMC filter, Standard Control Program, boards without coating, pedestal with output on the long side, output busbar set for motor, base and wall mounting brackets, one set of manuals. Preassembled unit. U4 Drive module (USA). When no options are selected: 6-pulse diode bridge, open chassis, top entry, side exit, no control panel, no EMC filter, US version of the Standard Control Program (three-wire start/stop as default setting), common mode filter in frame size R8, boards without coating, pedestal with output on the long side, output busbar set for motor, base and wall mounting brackets, one set of manuals. Pre-assembled unit. Size Refer to Technical data: IEC ratings or NEMA ratings in Hardware Manual [3AFE68360323 (Engllish)]. Voltage range 2 208/220/230/240 VAC (nominal rating in bold) 3 380/400/415 VAC 5 380/400/415/440/460/480/500 VAC 7 525/575/600/690 VAC + options Resistor braking D150 brake chopper and busbars for brake resistor and DC connection Filter E210 EMC/RFI filter for second environment TN/IT (grounded/ungrounded) system E208 common mode filter Pedestal and output 0H354 no pedestal busbars Control panel J400 control panel including a 3-metre panel connection cable J410 RPMP-11 control panel mounting platform kit including a 3-metre panel connection cable but no control panel J413 RPMP-21 control panel holder Fieldbus K... Refer to ACS800 Ordering Information (EN code: 64556568). I/O L... Control program N... Language of manual R... Specialities P901 coated boards Safety features Q950 Prevention of Unexpected Start, 500 mm (19.68 in.) cable outside the drive module in frame size R7, 600 mm (23.62 in.) cable outside the drive module in frame size R8. Selection Product series Type
27
Type code for ACS800-04M non-pre-assembled units (delivered as kits) Alternatives ACS800 product series 04M Drive module. When no options are selected: 6-pulse diode input bridge, IP 00, top entry, RDCU drive control unit, Standard Control Program, boards without coating, one set of manuals. No pedestal, no output busbars, no control panel, no EMC filter. Delivered as kits. Size Refer to Technical data: IEC ratings in Hardware Manual [3AFE68360323 (Engllish)]. Voltage range 2 208/220/230/240 VAC (nominal rating in bold) 3 380/400/415 VAC 5 380/400/415/440/460/480/500 VAC 7 525/575/600/690 VAC + options Shrouds B060 Frame size R7: clear plastic shrouds for bottom exit kit (+H352) and input terminals. Frame size R8: clear plastic shrouds for vertical busbars and input terminals in bookshelf mounting (+H354) Resistor braking D150 brake chopper Filter E202 EMC/RFI filter for first environment TN (grounded) system, restricted (the A limits) E210 EMC/RFI filter for second environment TN/IT (grounded/ungrounded) system E208 common mode filter Pedestal and output H352 bottom exit kit for frame size R7 busbars H354 pedestal with output on the long side (bookshelf) H355 vertical busbars and support brackets for AC output connection H356 pedestal (and adapter with +H360) busbar kit for brake resistor and DC connection H360 pedestal with output on the short side (flat) H362 vertical busbars (and support brackets with +H360) for DC output connection H363 busbar kit for DC and brake outputs on different long sides of the pedestal (+H356 required, not available for +H360) Control panel J400 control panel including a 3-metre panel connection cable J410 RPMP-11 control panel mounting platform kit including a 3-metre panel connection cable but no control panel J413 RPMP-21 control panel holder Fieldbus K... Refer to ACS800 Ordering Information (EN code: 64556568). I/O L... Control program N... Language of manual R... Specialities P901 coated boards Safety features Q950 Prevention of Unexpected Start, 500 mm (19.68 in.) cable outside the drive module in frame size R7, 600 mm (23.62 in.) cable outside the drive module in frame size R8. Selection Product series Type
28
Control interfaces
This diagram shows the control interfaces and the main circuit of the drive.
Motor control and I/O board (RMIO) External control via analogue/digital inputs and outputs
Optional module 1: RMBA, RAIO, RDIO, RDNA, RLON, RIBA, RPBA, RCAN, RCNA, RMBP, RETA, RRIA or RTAC Optional module 2: RTAC, RAIO, RRIA or RDIO DDCS communication option module: RDCO-01, RDCO-02 or RDCO-03
Input power
Output power
Brake chopper (optional)
R- UDC+ UDCR+
29
Connections of the Drive Control Unit (RDCU) in frame sizes R7 and R8

ACS800-04 drive module Protective tube AINT 3 m (118 in.)
80 (3.1 5)
4.5 (0.18)
80 (3.15)
Shield
APOW 2100 mm (83 in.)
Shielded 6-pin modular connector Control panel mounting platform kit (RPMP-11, optional)
To RMIO
3 m (118 in.)
External control connections to RMIO board
Drive control unit RDCU which contains motor control and I/O board RMIO
Control panel CDP312R (optional)
Operation This table describes the operation of the main circuit in short.
Component six-pulse rectifier capacitor bank six-pulse IGBT inverter Description converts the three-phase AC voltage to DC voltage energy storage which stabilizes the intermediate circuit DC voltage converts the DC voltage to AC voltage and vice versa. The motor operation is controlled by switching the IGBTs.
30
Printed circuit boards The drive contains the following printed circuit boards as standard: main circuit board (AINT) motor control and I/O board (RMIO) with a fibre optic link to the AINT board input bridge control board (AINP) input bridge protection board (AIBP) which includes snubbers for the thyristors and varistors power supply board (APOW) gate driver control board (AGDR) diagnostics and panel interface board (ADPI) brake chopper control board (ABRC) with option +D150 Motor control The motor control is based on the Direct Torque Control (DTC) method. Two phase currents and DC link voltage are measured and used for the control. The third phase current is measured for earth fault protection.
31
Mechanical installation
This chapter describes the mechanical installation of the drive cabinet generally. Follow the specific instructions given by the panel builder. For the mechanical assembly and dimensional drawings of the drive module, refer to ACS800-04/04M/ U4 Cabinet Installation [3AFE68360323 (English)].
Before installation
Delivery check The drive delivery contains: drive cabinet including factory installed options such as optional modules (inserted onto the RMIO board in the RDCU unit) residual voltage warning stickers hardware manual appropriate firmware manuals and guides appropriate optional module manuals delivery documents. Requirements for the installation site Check the installation site according to the requirements below. See Technical data for the allowed operation conditions of the drive. Cooling air flow Provide the drive with the amount of clean cooling air given in Technical data / IEC data or NEMA data.
32
Cable channel in the floor below the cabinet When a cable channel is constructed below the cabinet, ensure that cabinet weight lies on the sections which the floor carries.
Example cabinet frame viewed from above Example cabinet: side view
Cables
With heavy cabinets, support the structural C-sections from below.
Prevent the cooling air flow from the cable channel to the cabinet by bottom plates. To ensure the degree of protection for the cabinet use the original bottom plates delivered with the unit. With user-defined cable entries take care of the degree of protection, fire protection and EMC compliance.
Fastening the cabinet to the floor and wall

Fasten the cabinet to the floor and wall/roof according to the panel builders instructions, e.g. with outside fastening brackets or by fastening holes inside the cabinet.
Electric welding
It is not recommended to fasten the cabinet by welding. If the preferred fastening methods (clamping or bolting through the holes inside the cabinet) cannot be used, proceed as follows: Connect the return conductor of the welding equipment to the cabinet frame at the bottom within 0.5 metres of the welding point. WARNING! If the welding return wire is connected improperly, the welding circuit may damage electronic circuits in the cabinet. Ensure that the welding fumes are not inhaled.
33
Planning the electrical installation

This chapter contains the instructions that you must follow when selecting the motor, cables, protections, cable routing and way of operation for the drive system. Note: The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.

This chapter applies to the ACS800-01/U1, ACS800-11/U11, ACS800-31/U31, ACS800-02/U2, ACS800-04/U4, and ACS800-07/U7 types up to -0610-x. Note: All options described in this chapter are not available for all products. Check the availability from section Type code on page 26.
Motor selection and compatibility

1. Select the motor according to the rating tables in chapter Technical Data. Use the DriveSize PC tool if the default load cycles are not applicable. 2. Check that the motor ratings lie within the allowed ranges of the drive control program: motor nominal voltage is 1/2 ... 2 UN of the drive motor nominal current is 1/6 ... 2 I2hd of the drive in DTC control and 0 ... 2 I2hd in scalar control. The control mode is selected by a drive parameter.
34
3. Check that the motor voltage rating meets the application requirements:
If the drive is equipped with and then the motor voltage rating should be UN UACeq1 UN UACeq2
diode supply no resistor braking is in use ACS800-01, -U1, -02, -U2, frequent or long term brake cycles will -04, -04M, -U4 -07, -U7 be used IGBT supply ACS800-11, -U11, -31, -U31, -17, -37 DC link voltage will not be increased from nominal (parameter setting) DC link voltage will be increased from nominal (parameter setting)
UN
= rated input voltage of the drive
UACeq1 = UDC/1.35 UACeq2 = UDC/1.41 UACeq is the equivalent AC power source voltage of the drive in V AC. UDC is the maximum DC link voltage of the drive in V DC. For resistor braking: UDC= 1.21 nominal DC link voltage. For units with IGBT supply: See the parameter value. (Note: Nominal DC link voltage is UN 1.35 or UN 1.41 in V DC.)
See notes 6 and 7 below the Requirements table, page 38. 4. Consult the motor manufacturer before using a motor in a drive system where the motor nominal voltage differs from the AC power source voltage. 5. Ensure that the motor insulation system withstands the maximum peak voltage in the motor terminals. See the Requirements table below for the required motor insulation system and drive filtering. Example 1: When the supply voltage is 440 V and a drive with a diode supply is operating in motor mode only, the maximum peak voltage in the motor terminals can be approximated as follows: 440 V 1.35 2 = 1190 V. Check that the motor insulation system withstands this voltage. Example 2: When the supply voltage is 440 V and the drive is equipped with an IGBT supply, the maximum peak voltage in the motor terminals can be approximated as follows: 440 V 1.41 2 = 1241 V. Check that the motor insulation system withstands this voltage.
35
Protecting the motor insulation and bearings The output of the drive comprises regardless of output frequency pulses of approximately 1.35 times the equivalent mains network voltage with a very short rise time. This is the case with all drives employing modern IGBT inverter technology. The voltage of the pulses can be almost double at the motor terminals, depending on the attenuation and reflection properties of the motor cable and the terminals. This in turn can cause additional stress on the motor and motor cable insulation. Modern variable speed drives with their fast rising voltage pulses and high switching frequencies can generate current pulses that flow through the motor bearings, which can gradually erode the bearing races and rolling elements. The stress on motor insulation can be avoided by using optional ABB du/dt filters. du/dt filters also reduce bearing currents. To avoid damage to motor bearings, the cables must be selected and installed according to the instructions given in the hardware manual. In addition, insulated Nend (non-driven end) bearings and output filters from ABB must be used according to the following table. Two types of filters are used individually or in combinations: optional du/dt filter (protects motor insulation system and reduces bearing currents). common mode filter (mainly reduces bearing currents).
36
Requirements table
The following table shows how to select the motor insulation system and when an optional ABB du/dt filter, insulated N-end (non-driven end) motor bearings and ABB common mode filters are required. The motor manufacturer should be consulted regarding the construction of the motor insulation and additional requirements for explosion-safe (EX) motors. Failure of the motor to fulfil the following requirements or improper installation may shorten motor life or damage the motor bearings and voids the warranty.
Motor type Manufacturer Nominal mains voltage (AC line voltage) Requirement for Motor insulation system ABB du/dt filter, insulated N-end bearing and ABB common mode filter PN < 100 kW and frame size < IEC 315 PN < 134 HP and frame size < NEMA 500 A B B Randomwound M2_ and M3_ UN < 500 V Standard or Reinforced 600 V < UN < 690 V Reinforced Form-wound HX_ and AM_ 380 V < UN < 690 V Standard + du/dt n.a. +N + du/dt + N + N + CMF + N + CMF + du/dt + N + CMF PN < 500 kW: + N + CMF PN > 500 kW: + N + CMF + du/dt Old* formwound HX_ and modular Randomwound HX_ and AM_ ** 380 V < UN < 690 V Check with the motor manufacturer. Enamelled wire with fibre glass 500 V < UN < 690 V taping 0 V < UN < 500 V + du/dt with voltages over 500 V + N + CMF + du/dt +N + du/dt + N 500 V < UN < 600 V Standard 100 kW < PN < 350 kW or frame size > IEC 315 134 HP < PN < 469 HP or frame size > NEMA 500 PN > 350 kW or frame size > IEC 400 PN > 469 HP or frame size > NEMA 580 + N + CMF + du/dt + N + CMF
+ N + CMF + du/dt + N + CMF
37
Motor type Manufacturer
Nominal mains voltage (AC line voltage)
Requirement for Motor insulation system ABB du/dt filter, insulated N-end bearing and ABB common mode filter PN < 100 kW and frame size < IEC 315 PN < 134 HP and frame size < NEMA 500 100 kW < PN < 350 kW or frame size > IEC 315 134 HP < PN < 469 HP or frame size > NEMA 500 + N or CMF + du/dt + N or + du/dt + CMF or Reinforced: LL = 1600 V, 0.2 microsecond rise time + N or CMF + N + CMF PN > 350 kW or frame size > IEC 400 PN > 469 HP or frame size > NEMA 580 + N + CMF + du/dt + N + CMF
N O N A B B
Randomwound and form-wound
UN < 420 V
Standard: LL = 1300 V
+ du/dt
420 V < UN < 500 V Standard: LL = 1300 V
500 V < UN < 600 V Reinforced: LL = + du/dt 1600 V
+ du/dt + N or + du/dt + CMF
+ du/dt + N + CMF
or Reinforced: LL = 1800 V 600 V < UN < 690 V Reinforced: LL = + du/dt 1800 V Reinforced: LL = 2000 V, 0.3 microsecond rise time *** * ** manufactured before 1.1.1998 For motors manufactured before 1.1.1998, check for additional instructions with the motor manufacturer. + N or CMF + du/dt + N N + CMF + N + CMF + du/dt + N + CMF N + CMF
*** If the intermediate DC circuit voltage of the drive is increased from the nominal level by resistor braking or by the IGBT Supply Control Program (parameter selectable function), check with the motor manufacturer if additional output filters are needed in the applied drive operation range.
Note 1: The abbreviations used in the table are defined below.

Abbreviation UN LL PN du/dt CMF N n.a. Definition nominal voltage of the supply network peak line-to-line voltage at motor terminals which the motor insulation must withstand motor nominal power du/dt filter at the output of the drive +E205 common mode filter +E208 N-end bearing: insulated motor non-driven end bearing Motors of this power range are not available as standard units. Consult the motor manufacturer.
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Note 2: Explosion-safe (EX) motors The motor manufacturer should be consulted regarding the construction of the motor insulation and additional requirements for explosion-safe (EX) motors. Note 3: High-output motors and IP 23 motors For motors with higher rated output than what is stated for the particular frame size in EN 50347 (2001) and for IP 23 motors, the requirements of ABB random-wound motor series M3AA, M3AP, M3BP are given below. For other motor types, see the Requirements table above. Apply the requirements of range 100 kW < PN < 350 kW to motors with PN < 100 kW. Apply the requirements of range PN > 350 kW to motors within the range 100 kW < PN < 350 kW. In other cases, consult the motor manufacturer.
Manufacturer Motor type Nominal mains voltage (AC line voltage) Requirement for Motor insulation system ABB du/dt filter, insulated N-end bearing and ABB common mode filter PN < 55 kW PN < 74 HP A B B Randomwound M3AA, M3AP, M3BP UN < 500 V Standard or Reinforced 600 V < UN < 690 V Reinforced + du/dt +N + du/dt + N + N + CMF + du/dt + N + CMF + du/dt 55 kW < PN < 200 kW 74 HP < PN < 268 HP +N + du/dt + N PN > 200 kW PN > 268 HP + N + CMF + du/dt + N + CMF
500 V < UN < 600 V Standard
Note 4: HXR and AMA motors All AMA machines (manufactured in Helsinki) for drive systems have form-wound windings. All HXR machines manufactured in Helsinki starting 1.1.1998 have form-wound windings. Note 5: ABB motors of types other than M2_, M3_, HX_ and AM_ Use the selection criteria given for non-ABB motors. Note 6: Resistor braking of the drive When the drive is in braking mode for a large part of its operation time, the intermediate circuit DC voltage of the drive increases, the effect being similar to increasing the supply voltage by up to 20 percent. The voltage increase should be taken into consideration when determining the motor insulation requirement. Example: Motor insulation requirement for a 400 V application must be selected as if the drive were supplied with 480 V. Note 7: Drives with an IGBT supply unit If voltage is raised by the drive (this is a parameter selectable function), select the motor insulation system according to the increased intermediate circuit DC voltage level, especially in the 500 V supply voltage range.
39
Note 8: Calculating the rise time and the peak line-to-line voltage The peak line-to-line voltage at the motor terminals generated by the drive as well as the voltage rise time depend on the cable length. The requirements for the motor insulation system given in the table are worst case requirements covering installations with 30 metre and longer cables. The rise time can be calculated as follows: t = 0.8 LL/(du/dt). Read LL and du/dt from the diagrams below. Multiply the values of the graph by the supply voltage (UN). In case of drives with an IGBT supply unit or resistor braking, the LL and du/dt values are approximately 20% higher. 3.0 2.5 2.0 1.5 1.0 0.5 0.0 100 200 300 Cable length (m) With du/dt Filter du/dt ------------ (1/ s) UN LL/UN 5.5 5.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 100 200 300 Cable length (m) Without du/dt Filter LL/UN du/dt ------------ (1/ s) UN
Note 9: Sine filters protect the motor insulation system. Therefore, du/dt filter can be replaced with a sine filter. The peak phase-to-phase voltage with the sine filter is approximately 1.5 UN. Note 10: Common mode filter is available as a plus code option (+E208) or as a separate kit (one box including three rings for one cable).
Permanent magnet synchronous motor

Only one permanent magnet motor can be connected to the inverter output. It is recommended to install a safety switch between the permanent magnet synchronous motor and the drive output. The switch is needed to isolate the motor during any maintenance work on the drive.
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Supply connection
Disconnecting device (disconnecting means) ACS800-01, ACS800-U1, ACS800-11, ACS800-U11, ACS800-31, ACS800-U31, ACS800-02 and ACS800-U2 without enclosure extension, ACS800-04, ACS800-U4 Install a hand-operated input disconnecting device (disconnecting means) between the AC power source and the drive. The disconnecting device must be of a type that can be locked to the open position for installation and maintenance work. ACS800-02 and ACS800-U2 with enclosure extension, ACS800-07 and ACS800-U7 These units are equipped with a hand-operated input disconnecting device (disconnecting means) which isolates the drive and the motor from the AC power as standard. The disconnecting device does not, however, isolate the input busbars from the AC power. Therefore, during installation and maintenance work on the drive, the input cables and busbars must be isolated from the input power with a disconnector at the distribution board or at the supplying transformer. EU To meet the European Union Directives, according to standard EN 60204-1, Safety of Machinery, the disconnecting device must be one of the following types: switch-disconnector of utilization category AC-23B (EN 60947-3) disconnector that has an auxiliary contact that in all cases causes switching devices to break the load circuit before the opening of the main contacts of the disconnector (EN 60947-3) circuit breaker suitable for isolation in accordance with EN 60947-2. US The disconnecting means must conform to the applicable safety regulations. Fuses See section Thermal overload and short-circuit protection. Main contactor If used, dimension the contactor according to the nominal voltage and current of the drive. The utilization category (IEC 947-4) is AC-1.
41
Thermal overload and short-circuit protection

Thermal overload protection of the drive and the input and motor cables The drive protects itself and the input and motor cables against thermal overload when the cables are dimensioned according to the nominal current of the drive. No additional thermal protection devices are needed. WARNING! If the drive is connected to multiple motors, a separate thermal overload switch or a circuit breaker must be used for protecting each cable and motor. These devices may require a separate fuse to cut off the short-circuit current. Thermal overload protection of the motor According to regulations, the motor must be protected against thermal overload and the current must be switched off when overload is detected. The drive includes a motor thermal protection function that protects the motor and switches off the current when necessary. Depending on a drive parameter value, the function either monitors a calculated temperature value (based on a motor thermal model) or an actual temperature indication given by motor temperature sensors. The user can tune the thermal model further by feeding in additional motor and load data. The most common temperature sensors are: motor sizes IEC180225: thermal switch (e.g. Klixon) motor sizes IEC200250 and larger: PTC or Pt100. See the firmware manual for more information on the motor thermal protection, and the connection and use of the temperature sensors. Protection against short-circuit in the motor cable The drive protects the motor cable and motor in a short-circuit situation when the motor cable is dimensioned according to the nominal current of the drive. No additional protection devices are needed.
42
Protection against short-circuit inside the drive or in the supply cable Arrange the protection according to the following guide lines.
Circuit diagram Drive type Short-circuit protection
Distribution board 1)
DRIVE IS NOT EQUIPPED WITH INPUT FUSES ACS800-01 Drive or drive ACS800-U1 module Input cable ACS800-02
M 3~
Protect the drive and input cable with fuses or a circuit breaker. See footnotes 1) and ACS800-U2+0C111 2). ACS800-11 ACS800-U11 ACS800-31 ACS800-U31
I>
2)
M 3~
ACS800-04 ACS800-U4
DRIVE IS EQUIPPED WITH INPUT FUSES ACS800-02+C111 Distribution board 3) Input cable 4) Drive ACS800-U2 ACS800-07
~
Drive 4) I>
M 3~
ACS800-U7
Protect the input cable with fuses or a circuit breaker according to local regulations. See footnotes 3) and 4).
M 3~
1) Size the fuses according to instructions given in chapter Technical data. The fuses will protect the input cable in short-circuit situations, restrict drive damage and prevent damage to adjoining equipment in case of a short-circuit inside the drive.
43
2) Circuit breakers which have been tested by ABB with the ACS800 can be used. Fuses must be used with other circuit breakers. Contact your local ABB representative for the approved breaker types and supply network characteristics. The protective characteristics of circuit breakers depend on the type, construction and settings of the breakers. There are also limitations pertaining to the short-circuit capacity of the supply network. WARNING! Due to the inherent operating principle and construction of circuit breakers, independent of the manufacturer, hot ionized gases may escape from the breaker enclosure in case of a short-circuit. To ensure safe use, special attention must be paid to the installation and placement of the breakers. Follow the manufacturers instructions. Note: Circuit breakers must not be used without fuses in the USA. 3) Size the fuses according to local safety regulations, appropriate input voltage and the rated current of the drive (see chapter Technical data). 4) ACS800-02 units and ACS800-07 units with enclosure extension are equipped with aR fuses as standard. ACS800-U2 and ACS800-U7 units are equipped with T/L fuses as standard. The fuses restrict drive damage and prevent damage to adjoining equipment in case of a short-circuit inside the drive.
Ground fault protection

The drive is equipped with an internal ground fault protective function to protect the unit against ground faults in the motor and motor cable. This is not a personal safety or a fire protection feature. The ground fault protective function can be disabled with a parameter, refer to the appropriate ACS800 Firmware Manual. The EMC filter of the drive includes capacitors connected between the main circuit and the frame. These capacitors and long motor cables increase the ground leakage current and may cause fault current circuit breakers to function.
Emergency stop devices

For safety reasons, install the emergency stop devices at each operator control station and at other operating stations where emergency stop may be needed. Note: Pressing the stop key ( ) on the control panel of the drive does not generate an emergency stop of the motor or separate the drive from dangerous potential. ACS800-02/U2 with enclosure extension and ACS800-07/U7 An emergency stop function is optionally available for stopping and switching off the whole drive. Two stop categories according to IEC/EN 60204-1 (1997) are available: immediate removal of power (Category 0 for ACS800-02/U2 and ACS800-07/U7) and controlled emergency stop (Category 1 for ACS800-07/U7). Restarting after an emergency stop After an emergency stop, the emergency stop button must be released and the drive started by turning the operating switch of the drive from position ON to START.
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Power-loss ride-through function

The power-loss ride-through function is activated when parameter 20.06 UNDERVOLTAGE CTRL is set to ON (default in Standard Control Program). ACS800-07/U7 units without line contactor The power-loss ride-through funtion is not in use. ACS800-07/U7 units with line contactor (+F250) The power-loss ride-through funtion is enabled by connecting RMIO board terminals X22:8 and X22:11 with a jumper.
X2 / RMIO board X22 1 2 3 4 5 6 7 8 9 10 11
K13
22 21
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Prevention of Unexpected Start

The ACS800-01/U1, ACS800-04/U4, ACS800-11/U11, ACS800-31/U31 and ACS800-07/U7 can be equipped with an optional Prevention of Unexpected Start function according to standards IEC/EN 60204-1: 1997; ISO/DIS 14118: 2000 and EN 1037: 1996. The Prevention of Unexpected Start function disables the control voltage of the power semiconductors, thus preventing the inverter from generating the AC voltage required to rotate the motor. By using this function, short-time operations (like cleaning) and/or maintenance work on non-electrical parts of the machinery can be performed without switching off the AC power supply to the drive. The operator activates the Prevention of Unexpected Start function by opening a switch on a control desk. An indicating lamp on the control desk will light, signalling that the prevention is active. The switch can be locked out. The user must install on a control desk near the machinery: switching/disconnecting device for the circuitry. Means shall be provided to prevent inadvertent, and/or mistaken closure of the disconnecting device. EN 60204-1: 1997. indicating lamp; on = starting the drive is prevented, off = drive is operative. ACS800-01/U1, ACS800-04/U4, ACS800-11/U11, ACS800-31/U31: safety relay (type BD5935 has been approved by ABB) For connections to the drive, see chapter Installation of AGPS board (Prevention of Unexpedted Start, +Q950) or the circuit diagram delivered with the drive (ACS80007/U7). WARNING! The Prevention of Unexpected Start function does not disconnect the voltage of the main and auxiliary circuits from the drive. Therefore maintenance work on electrical parts of the drive or the motor can only be carried out after isolating the drive system from the main supply. Note: If a running drive is stopped by using the Prevention of Unexpected Start function, the drive will cut off the motor supply voltage and the motor will coast to stop.
46
Selecting the power cables

General rules Dimension the mains (input power) and motor cables according to local regulations: The cable must be able to carry the drive load current. See chapter Technical data for the rated currents. The cable must be rated for at least 70 C maximum permissible temperature of conductor in continuous use. For US, see Additional US requirements. The inductance and impedance of the PE conductor/cable (grounding wire) must be rated according to permissible touch voltage appearing under fault conditions (so that the fault point voltage will not rise excessively when a ground fault occurs). 600 V AC cable is accepted for up to 500 V AC. 750 V AC cable is accepted for up to 600 V AC. For 690 V AC rated equipment, the rated voltage between the conductors of the cable should be at least 1 kV. For drive frame size R5 and larger, or motors larger than 30 kW (40 HP), symmetrical shielded motor cable must be used (figure below). A four-conductor system can be used up to frame size R4 with up to 30 kW (40 HP) motors, but shielded symmetrical motor cable is always recommended. The shield(s) of motor cable(s) must have 360 bonding at both ends. Note: When continuous metal conduit is employed, shielded cable is not required. The conduit must have bonding at both ends as with cable shield. A four-conductor system is allowed for input cabling, but shielded symmetrical cable is recommended. To operate as a protective conductor, the shield conductivity must be as follows when the protective conductor is made of the same metal as the phase conductors:
Cross-sectional area of the phase conductors S (mm2) S < 16 16 < S < 35 35 < S Minimum cross-sectional area of the corresponding protective conductor Sp (mm2) S 16 S/2
Compared to a four-conductor system, the use of symmetrical shielded cable reduces electromagnetic emission of the whole drive system as well as the stress on motor insulation, bearing currents and wear. The motor cable and its PE pigtail (twisted shield) should be kept as short as possible in order to reduce high-frequency electromagnetic emission, as well as stray currents outside the cable and capacitive current (relevant in power range below 20 kW).
47
Alternative power cable types Power cable types that can be used with the drive are represented below.
Recommended Symmetrical shielded cable: three phase conductors and a concentric or otherwise symmetrically constructed PE conductor, and a shield PE conductor and shield Shield A separate PE conductor is required if the conductivity of the cable shield is < 50% of the conductivity of the phase conductor. Shield
PE
PE
A four-conductor system: three phase conductors and a protective conductor
PE
Shield
Not allowed for motor cables
Not allowed for motor cables with phase conductor cross section larger than 10 mm2 [motors > 30 kW (40 HP)].
Motor cable shield To effectively suppress radiated and conducted radio-frequency emissions, the shield conductivity must be at least 1/10 of the phase conductor conductivity. The requirements are easily met with a copper or aluminium shield. The minimum requirement of the motor cable shield of the drive is shown below. It consists of a concentric layer of copper wires with an open helix of copper tape or copper wire. The better and tighter the shield, the lower the emission level and bearing currents.
Insulation jacket Copper wire screen Helix of copper tape or copper wire Inner insulation
Cable core
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Additional US requirements Type MC continuous corrugated aluminum armor cable with symmetrical grounds or shielded power cable must be used for the motor cables if metallic conduit is not used. For the North American market, 600 V AC cable is accepted for up to 500 V AC. 1000 V AC cable is required above 500 V AC (below 600 V AC). For drives rated over 100 amperes, the power cables must be rated for 75 C (167 F). Conduit Separate parts of a conduit must be coupled together, bridge the joints with a ground conductor bonded to the conduit on each side of the joint. Bond the conduits also to the drive enclosure and motor frame. Use separate conduits for input power, motor, brake resistor, and control wiring. When conduit is employed, type MC continuous corrugated aluminium armor cable or shielded cable is not required. A dedicated ground cable is always required. Note: Do not run motor wiring from more than one drive in the same conduit. Armored cable / shielded power cable Six conductor (3 phases and 3 ground) type MC continuous corrugated aluminum armor cable with symmetrical grounds is available from the following suppliers (trade names in parentheses): Anixter Wire & Cable (Philsheath) BICC General Corp (Philsheath) Rockbestos Co. (Gardex) Oaknite (CLX). Shielded power cables are available from Belden, LAPPKABEL (LFLEX) and Pirelli.
Power factor compensation capacitors

Power factor compensation is not needed with AC drives. However, if a drive is to be connected in a system with compensation capacitors installed, note the following restrictions. WARNING! Do not connect power factor compensation capacitors or harmonic filters to the motor cables (between the drive and the motor). They are not meant to be used with AC drives and can cause permanent damage to the drive or themselves.
49
If there are power factor compensation capacitors in parallel with the three phase input of the drive: 1. Do not connect a high-power capacitor to the power line while the drive is connected. The connection will cause voltage transients that may trip or even damage the drive. 2. If capacitor load is increased/decreased step by step when the AC drive is connected to the power line: Ensure that the connection steps are low enough not to cause voltage transients that would trip the drive. 3. Check that the power factor compensation unit is suitable for use in systems with AC drives i.e. harmonic generating loads. In such systems, the compensation unit should typically be equipped with a blocking reactor or harmonic filter.
Equipment connected to the motor cable

Installation of safety switches, contactors, connection boxes, etc. To minimize the emission level when safety switches, contactors, connection boxes or similar equipment are installed in the motor cable between the drive and the motor: EU: Install the equipment in a metal enclosure with 360 degrees grounding for the shields of both the incoming and outgoing cable, or connect the shields of the cables otherwise together. US: Install the equipment in a metal enclosure in a way that the conduit or motor cable shielding runs consistently without breaks from the drive to the motor. Bypass connection WARNING! Never connect the supply power to the drive output terminals U2, V2 and W2. If frequent bypassing is required, employ mechanically connected switches or contactors. Mains (line) voltage applied to the output can result in permanent damage to the unit. Before opening a contactor (DTC control mode selected) Stop the drive and wait for the motor to stop before opening a contactor between the output of the drive and the motor when the DTC control mode is selected. See the appropriate ACS800 control program firmware manual for the required parameter settings. Otherwise, the contactor will be damaged. In scalar control, the contactor can be opened with the drive running.
50
Protecting the relay output contacts and attenuating disturbances in case of inductive loads
Inductive loads (relays, contactors, motors) cause voltage transients when switched off. The relay contacts on the RMIO board are protected with varistors (250 V) against overvoltage peaks. In spite of this, it is highly recommended to equip inductive loads with noise attenuating circuits [varistors, RC filters (AC) or diodes (DC)] in order to minimize the EMC emission at switch-off. If not suppressed, the disturbances may connect capacitively or inductively to other conductors in the control cable and form a risk of malfunction in other parts of the system. Install the protective component as close to the inductive load as possible. Do not install protective components at the RMIO board terminal block.
RMIO
Relay outputs Varistor

X25
1 230 V AC RC filter 2 3
X26
RO1 RO1 RO1 RO2 RO2 RO2 RO3 RO3 RO3
1 230 V AC Diode 2 3
X27
1 24 V DC 2 3
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Selecting the control cables

All control cables must be shielded. Use a double-shielded twisted pair cable (Figure a, e.g. JAMAK by NK Cables, Finland) for analogue signals. This type of cable is recommended for the pulse encoder signals also. Employ one individually shielded pair for each signal. Do not use common return for different analogue signals. A double-shielded cable is the best alternative for low-voltage digital signals but single-shielded twisted pair cable (Figure b) is also usable.
a A double-shielded twisted pair cable
b A single-shielded twisted pair cable
Run analogue and digital signals in separate, shielded cables. Relay-controlled signals, providing their voltage does not exceed 48 V, can be run in the same cables as digital input signals. It is recommended that the relay-controlled signals be run as twisted pairs. Never mix 24 VDC and 115/230 V AC signals in the same cable. Relay cable The cable type with braided metallic screen (e.g. LFLEX by LAPPKABEL, Germany) has been tested and approved by ABB. Control panel cable In remote use, the cable connecting the control panel to the drive must not exceed 3 metres (10 ft). The cable type tested and approved by ABB is used in control panel option kits.
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Connection of a motor temperature sensor to the drive I/O

WARNING! IEC 60664 requires double or reinforced insulation between live parts and the surface of accessible parts of electrical equipment which are either nonconductive or conductive but not connected to the protective earth. To fulfil this requirement, the connection of a thermistor (and other similar components) to the digital inputs of the drive can be implemented in three alternate ways: 1. There is double or reinforced insulation between the thermistor and live parts of the motor. 2. Circuits connected to all digital and analogue inputs of the drive are protected against contact and insulated with basic insulation (the same voltage level as the drive main circuit) from other low voltage circuits. 3. An external thermistor relay is used. The insulation of the relay must be rated for the same voltage level as the main circuit of the drive. For connection, see ACS800 Firmware Manual.
Installation sites above 2000 metres (6562 feet)

WARNING! Protect against direct contact when installing, operating and servicing the RMIO board wiring and optional modules attached to the board. The Protective Extra Low Voltage (PELV) requirements stated in EN 50178 are not fulfilled at altitudes above 2000 m (6562 ft).
Routing the cables

Route the motor cable away from other cable routes. Motor cables of several drives can be run in parallel installed next to each other. It is recommended that the motor cable, input power cable and control cables be installed on separate trays. Avoid long parallel runs of motor cables with other cables in order to decrease electromagnetic interference caused by the rapid changes in the drive output voltage. Where control cables must cross power cables make sure they are arranged at an angle as near to 90 degrees as possible. Do not run extra cables through the drive. The cable trays must have good electrical bonding to each other and to the grounding electrodes. Aluminium tray systems can be used to improve local equalizing of potential.
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A diagram of the cable routing is shown below.
Motor cable Drive Power cable min 300 mm (12 in.)
Input power cable min 200 mm (8 in.) 90 Control cables
Motor cable min 500 mm (20 in.)
Control cable ducts
230 V 24 V (120 V)
230 V 24 V (120 V)
Not allowed unless the 24 V cable is insulated for 230 V (120 V) or insulated with an insulation sleeving for 230 V (120 V).
Lead 24 V and 230 V (120 V) control cables in separate ducts inside the cabinet.
54
55
Electrical installation
This chapter instructs in the cabling of the drive.
Warnings
WARNING! Only qualified electricians are allowed to carry out the work described in this chapter. Follow the Safety instructions on the first pages of this manual. Ignoring the safety instructions can cause injury or death.
Checking the insulation of the assembly

Drive Every drive module has been tested for insulation between the main circuit and the chassis (2500 V rms 50 Hz for 1 second) at the factory. Therefore, do not make any voltage tolerance or insulation resistance tests (e.g. hi-pot or megger) on any part of the drive. Input cable Check the insulation of the input cable according to local regulations before connecting it to the drive. Motor and motor cable Check the insulation of the motor and motor cable as follows: 1. Check that the motor cable is disconnected from the drive output terminals U2, V2 and W2. 2. Measure the insulation resistances of the motor cable and the motor between each phase and the Protective Earth by using a measuring voltage of 1 kV DC. The insulation resistance must be higher than 1 Mohm.
M PE
ohm
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IT (ungrounded) systems
A drive equipped with no EMC filter or with EMC filter +E210 is suitable for IT (ungrounded systems). If the drive is equipped with EMC filter +E202, disconnect the filter before connecting the drive to an ungrounded system. For detailed instructions on how to do this, please contact your local ABB representative. WARNING! If a drive with EMC filter +E202 is installed on an IT system [an ungrounded power system or a high-resistance-grounded (over 30 ohms) power system], the system will be connected to earth potential through the EMC filter capacitors of the drive. This may cause danger or damage the unit.
Installation of optional EMC filter (+E202)

See ARFI-10 EMC Filter Installation Guide [3AFE68317941 (English)].
Cabinet
*CDP312R control panel
RDCU **Main contactor
Example wiring diagram
RMIO
*Line filter
**Motor temperature supervision **Switch fuse disconnector *Common mode filter **du/dt filter or **sine filter
ACS800-04 drive module
Supply
3~ Motor Temperature sensors for motor protection
**Brake resistor
Signal/ control
Alarm
The diagram below presents an example for the main wiring. Note that the diagram includes optional components which are not included in a basic delivery (marked *) and equipment not available as plus code options (marked **).
360 degrees grounding in first environment installations
57
58
Power cable connection diagram

Drive module INPUT U1 V1 W1 2) RUDC+ UDCR+ OUTPUT U2 V2 W2
1)
PE
(PE) PE (PE) * For alternatives, see Planning the electrical installation: Disconnecting device (disconnecting means)
4)
4)
5)
*
L1 L2
External brake resistor 3) L3
U1
V1
W1
Motor
1), 2) If shielded cable is used (not required but recommended) and the conductivity of the shield is < 50 % of the conductivity of the phase conductor, use a separate PE cable (1) or a cable with a grounding conductor (2). Ground the other end of the input cable shield or PE conductor at the distribution board. 3) 360 degrees grounding recommended at the cabinet entry if shielded cable 4) 360 degrees grounding required at the cabinet entry in first environment installations ** 5) Use a separate grounding cable if the conductivity of the cable shield is < 50 % of the conductivity of the phase conductor and there is no symmetrically constructed grounding conductor in the cable (see Planning the electrical installation / Selecting the power cables). Note: If there is a symmetrically constructed grounding conductor in the motor cable in addition to the conductive shield, connect the grounding conductor to the grounding terminal at the drive and motor ends. Do not use an asymmetrically constructed motor cable. Connecting its fourth conductor at the motor end increases bearing currents and causes extra wear.
Grounding of the motor cable shield at the cabinet entry Ground the cable shield 360 degrees at the lead-through of the cabinet. Grounding of the motor cable shield at the motor end For minimum radio frequency interference: ground the cable shield 360 degrees at the lead-through of the motor terminal box
360 degrees grounding
Conductive gaskets or ground the cable by twisting the shield as follows: flattened width > 1/5 length.
b > 1/5 a a b
**
First environment EMC compliance is defined in Technical data / CE marking.
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Grounding of the cable shields

To power terminals Example cable lead-through
Cable shield PE terminal of the cabinet or drive module EMC sleeve *
Strain relief
Strip this part of the cable *
Base plate Lead-through plate
Recommended for control cables Strain relief
EMI conductive cushion
Grommet Side view
Lead-through plate
* required for motor cables in first environment installations. First environment EMC compliance is defined in chapter Technical data / CE marking.
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Fastening US cable lugs

Example mounting US cable lugs can be connected directly to the output busbars or to the terminals as follows.
1/2 bolt
1 3/4
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Connections of the RDCU

The RDCU drive control unit contains the RMIO board where the users control cables are connected. 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.
Control panel Internal power supply cable coming from the drive module Note: The lowest pin (ExtPower) is not in use. Even when the RMIO board is powered from an external power supply, do not use the ExtPower pin, but upper pins.
Strain relief
X34
TXD = transmitter
RXD = receiver
Ffibre optic cables coming from the drive module to the RMIO board
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Connecting the control cables to the RMIO board

Connect the control cables as described below. Connect the conductors to the appropriate detachable terminals of the RMIO board [refer to chapter Motor control and I/O board (RMIO)]. Tighten the screws to secure the connection. Make a 360 degrees EMC grounding at the cabinet entry in first environment installations. First environment EMC compliance is defined in Technical data / CE marking. Connecting the shield wires at RMIO board
Strain relief
1 2 3 4
Strain relief
Insulation
Double-shielded cable
Single-shielded cable
Single-shielded cable: Twist the grounding wires of the outer shield and connect them to the nearest grounding clamp. Double-shielded cable: Connect the inner shields and the grounding wires of the outer shield to the nearest grounding clamp. Do not connect shields of different cables to the same grounding clamp. Leave the other end of the shield unconnected or ground it indirectly via a few nanofarads high-frequency capacitor (e.g. 3.3 nF / 630 V). The shield can also be grounded directly at both ends if they are in the same ground line with no significant voltage drop between the end points. Keep the signal wire pairs twisted as close to the terminals as possible. Twisting the wire with its return wire reduces disturbances caused by inductive coupling. Securing the control cables mechanically Use strain relief clamps as shown above. Fasten the control cables to the cabinet frame.
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Settings of the cooling fan transformer

The voltage transformer of the cooling fan is located at the top right-hand corner of the drive module. Remove the front cover for adjusting the settings and replace the cover after setting.
Set to 220 V if the supply frequency is 60 Hz. Set to 230 V if the supply frequency is 50 Hz.
Set according to the supply voltage: 380 V, 400 V, 415 V, 440 V, 480 V or 500 V; or 525 V, 575 V, 600 V, 660 V or 690 V. Note: No need to set for 230 V units.
Installation of optional modules

The optional module (such as a fieldbus adapter, an I/O extension module and the pulse encoder interface) is inserted in the optional module slot of the RMIO board in the RDCU unit and fixed with two screws. See the appropriate optional module manual for the cable connections. Cabling of I/O and fieldbus modules
Grounding wire of the outer shield Alternative to a) As short as possible Strain relief with a cable tie
1 2 3 4
a) Shield
Module
64
Pulse encoder module cabling

Clamp as close to the terminals as possible. Alternative to a) As short as possible Strain relief with a cable tie
1 2 3 4
a)
12345678 123456
PULSE ENCODER INTERFACE
Note1: If the encoder is of unisolated type, ground the encoder cable at the drive end only. If the encoder is galvanically isolated from the motor shaft and the stator frame, ground the encoder cable shield at the drive and the encoder end. Note 2: Twist the pair cable wires. Note 3: The grounding wire of the outer shield of the cable can alternatively be connected to the SHLD terminal of the RTAC module.
CHASSIS
SHLD
9 8 67 A
Fibre optic link A DDCS fibre optic link is provided via the RDCO optional module for PC tools, master/follower link, NDIO, NTAC, NAIO, AIMA I/O module adapter and fieldbus adapter modules of type Nxxx. See RDCO Users Manual [3AFE64492209 (English)] for the connections. When installing multiple modules on the same channel, connect them in a ring.
Warning sticker
There are warning stickers in different languages inside the packing box of the drive. Attach a warning sticker in the local language onto the cover of the drive module.
345
+24V
V IN
+15V
V OUT
0V
0V
CHZ-
CHZ+
CHB-
CHB+
CHA-
CHA+
SHLD
X1
NODE ID
X2
CHB CHA WD/ INIT GND
C D B
12 F0 E
RTAC-01
65
Motor control and I/O board (RMIO)

This chapter shows external control connections to the RMIO board for the ACS800 Standard Control Program (Factory Macro) specifications of the inputs and outputs of the board.

This chapter applies to ACS800 units which employ RMIO-01 board from revision J onwards and RMIO-02 board from revision H onwards.
Note for the ACS800-02 with enclosure extension and the ACS800-07
The connections for the RMIO board shown below apply also to optional terminal block X2 available for the ACS800-02 and ACS800-07. The terminals of the RMIO board are wired to terminal block X2 internally. Terminals of X2 accept cables from 0.5 to 4.0 mm2 (22 to 12 AWG). Tightening torque for screw terminals is 0.4 to 0.8 Nm (0.3 to 0.6 lbf ft). For disconnecting wires from spring terminals, use a screw driver with a blade thickness of 0.6 mm (0.024 in.) and width of 3.5 mm (0.138 in.), e.g. PHOENIX CONTACT SZF 10,6X3,5.
Note on terminal labelling

Optional modules (Rxxx) may have identical terminal designations with the RMIO board.
66
Note on external power supply

External +24 V power supply for the RMIO board is recommended if the application requires a fast start after connecting the input power supply fieldbus communication is required when the input power supply is disconnected. The RMIO board can be supplied from an external power source via terminal X23 or X34 or via both X23 and X34. The internal power supply to terminal X34 can be left connected when using terminal X23. WARNING! If the RMIO board is supplied from an external power source via terminal X34, the loose end of the cable removed from the RMIO board terminal must be secured mechanically to a location where it cannot come into contact with electrical parts. If the screw terminal plug of the cable is removed, the wire ends must be individually insulated. Parameter settings In Standard Control Program, set parameter 16.9 CTRL BOARD SUPPLY to EXTERNAL 24V if the RMIO board is powered from an external supply.
67
External control connections (non-US) External control cable connections to the RMIO board for the ACS800 Standard Control Program (Factory Macro) are shown below. For external control connections of other control macros and programs, see the appropriate Firmware Manual.
RMIO Terminal block size: cables 0.3 to 3.3 mm2 (22 to 12 AWG) Tightening torque: 0.2 to 0.4 Nm (0.2 to 0.3 lbf ft) X2* X20 1 2 X21 1 2 3 4 5 6 7 8 9 10 11 12 X22 1 2 3 4 5 6 7 8 9 10 11 X23 1 2 X25 1 2 3 X26 1 2 3 X27 1 2 3 RMIO X20 1 2 X21 1 2 3 4 5 6 7 8 9 10 11 12 X22 1 2 3 4 5 6 7 8 9 10 11 X23 1 2 X25 1 2 3 X26 1 2 3 X27 1 2 3
VREFAGND VREF+ AGND AI1+ AI1AI2+ AI2AI3+ AI3AO1+ AO1AO2+ AO2DI1 DI2 DI3 DI4 DI5 DI6 +24VD +24VD DGND1 DGND2 DIIL +24V GND RO1 RO1 RO1 RO2 RO2 RO2 RO3 RO3 RO3
Reference voltage -10 VDC, 1 kohm < RL < 10 kohm Reference voltage 10 VDC, 1 kohm < RL < 10 kohm Speed reference 0(2) ... 10 V, Rin = 200 kohm By default, not in use. 0(4) ... 20 mA, Rin = 100 ohm By default, not in use. 0(4) ... 20 mA, Rin = 100 ohm Motor speed 0(4)...20 mA speed, RL < 700 ohm
=
rpm
0...motor nom.
Output current 0(4)...20 mA = 0...motor nom. current, RL < 700 ohm Stop/Start Forward/Reverse 1) Not in use Acceleration & deceleration select 2) Constant speed select 3) Constant speed select 3) +24 VDC max. 100 mA Digital ground Digital ground Start interlock (0 = stop) 4) Auxiliary voltage output and input, nonisolated, 24 VDC 250 mA 5) Relay output 1: ready
* optional terminal block in ACS800-02 and ACS800-07 1) Only effective if par. 10.03 is set to
REQUEST by the user.

2)
0 = open, 1 = closed parameters 22.02 and 22.03 parameters 22.04 and 22.05 See par. group 12 CONSTANT SPEEDS. 0 0 1 1 Set speed through AI1 Constant speed 1 Constant speed 2 Constant speed 3
DI4 Ramp times according to 0 1

3)
DI5 DI6 Operation 0 1 0 1

4)
See parameter 21.09 START INTRL FUNC. between this output and optional modules installed on the board.
5) Total maximum current shared
Relay output 2: running
Relay output 3: fault (-1)
Fault
68
External control connections (US) External control cable connections to the RMIO board for the ACS800 Standard Control Program (Factory Macro US version) are shown below. For external control connections of other control macros and programs, see the appropriate Firmware Manual.
RMIO Terminal block size: cables 0.3 to 3.3 mm (22 to 12 AWG) Tightening torque: 0.2 to 0.4 Nm (0.2 to 0.3 lbf ft)
2
rpm
* optional terminal block in ACS800-U2 and ACS800-U7 1) Only effective if par. 10.03 is set to
REQUEST by the user.

2)
0 = open, 1 = closed parameters 22.02 and 22.03 parameters 22.04 and 22.05 See par. group 12 CONSTANT SPEEDS. 0 0 1 1 Set speed through AI1 Constant speed 1 Constant speed 2 Constant speed 3
DI4 Ramp times according to 0 1

3)
DI5 DI6 Operation 0 1 0 1
4) See parameter 21.09 START INTRL
FUNC.
5) Total maximum current shared
between this output and optional modules installed on the board.
Fault
X2* X20 1 2 X21 1 2 3 4 5 6 7 8 9 10 11 12 X22 1 2 3 4 5 6 7 8 9 10 11 X23 1 2 X25 1 2 3 X26 1 2 3 X27 1 2 3
RMIO X20 1 2 X21 1 2 3 4 5 6 7 8 9 10 11 12 X22 1 2 3 4 5 6 7 8 9 10 11 X23 1 2 X25 1 2 3 X26 1 2 3 X27 1 2 3
VREF- Reference voltage -10 VDC, 1 kohm < RL < AGND 10 kohm VREF+ AGND AI1+ AI1AI2+ AI2AI3+ AI3AO1+ AO1AO2+ AO2DI1 DI2 DI3 DI4 DI5 DI6 +24VD +24VD DGND1 DGND2 DIIL +24V GND RO1 RO1 RO1 RO2 RO2 RO2 RO3 RO3 RO3 Reference voltage 10 VDC, 1 kohm < RL < 10 kohm Speed reference 0(2) ... 10 V, Rin = 200 kohm By default, not in use. 0(4) ... 20 mA, Rin = 100 ohm By default, not in use. 0(4) ... 20 mA, Rin = 100 ohm Motor speed 0(4)...20 mA speed, RL < 700 ohm
=
0...motor nom.
Output current 0(4)...20 mA = 0...motor nom. current, RL < 700 ohm Start ( ) Stop ( ) Forward/Reverse 1) Acceleration & deceleration select 2) Constant speed select 3) Constant speed select 3) +24 VDC max. 100 mA Digital ground Digital ground Start interlock (0 = stop) 4) Auxiliary voltage output and input, nonisolated, 24 VDC 250 mA 5) Relay output 1: ready
Relay output 2: running
Relay output 3: fault (-1)
69
RMIO board specifications

Analogue inputs
With Standard Control Program two programmable differential current inputs (0 mA / 4 mA ... 20 mA, Rin = 100 ohm) and one programmable differential voltage input (10 V / 0 V / 2 V ... +10 V, Rin = 200 kohm). Insulation test voltage Max. common mode voltage between the channels Common mode rejection ratio Resolution Inaccuracy The analogue inputs are galvanically isolated as a group. 500 VAC, 1 min 15 VDC > 60 dB at 50 Hz 0.025% (12 bit) for the -10 V ... +10 V input. 0.5% (11 bit) for the 0 ... +10 V and 0 ... 20 mA inputs. 0.5% (Full Scale Range) at 25 C (77 F). Temperature coefficient: 100 ppm/C ( 56 ppm/F), max.
Constant voltage output

Voltage Maximum load Applicable potentiometer +10 VDC, 0, -10 VDC 0.5% (Full Scale Range) at 25 C (77 F). Temperature coefficient: 100 ppm/C ( 56 ppm/F) max. 10 mA 1 kohm to 10 kohm
Auxiliary power output

Voltage Maximum current 24 VDC 10%, short circuit proof 250 mA (shared between this output and optional modules installed on the RMIO)
Analogue outputs
Resolution Inaccuracy Two programmable current outputs: 0 (4) to 20 mA, RL < 700 ohm 0.1% (10 bit) 1% (Full Scale Range) at 25 C (77 F). Temperature coefficient: 200 ppm/C ( 111 ppm/F) max.
Digital inputs
With Standard Control Program six programmable digital inputs (common ground: 24 VDC, -15% to +20%) and a start interlock input. Group isolated, can be divided in two isolated groups (see Isolation and grounding diagram below). Thermistor input: 5 mA, < 1.5 kohm 1 (normal temperature), > 4 kohm (high temperature), open circuit 0 (high temperature). 0
Insulation test voltage Logical thresholds Input current Filtering time constant
Internal supply for digital inputs (+24 VDC): short-circuit proof. An external 24 VDC supply can be used instead of the internal supply. 500 VAC, 1 min < 8 VDC 0, > 12 VDC 1 DI1 to DI 5: 10 mA, DI6: 5 mA 1 ms
70
Relay outputs
Switching capacity Minimum continuous current Maximum continuous current Insulation test voltage Three programmable relay outputs 8 A at 24 VDC or 250 VAC, 0.4 A at 120 VDC 5 mA rms at 24 VDC 2 A rms 4 kVAC, 1 minute
DDCS fibre optic link

With optional communication adapter module RDCO. Protocol: DDCS (ABB Distributed Drives Communication System)
24 VDC power input

Voltage Typical current consumption (without optional modules) Maximum current consumption 24 VDC 10% 250 mA 1200 mA (with optional modules inserted)
The terminals on the RMIO board as well as on the optional modules attachable to the board fulfil the Protective Extra Low Voltage (PELV) requirements stated in EN 50178 provided that the external circuits connected to the terminals also fulfil the requirements and the installation site is below 2000 m (6562 ft). Above 2000 m (6562 ft), see page 52.
71
Isolation and grounding diagram
X20 1 2 X21 1 2 3 4 5 6 7 8 9 10 11 12 X22 1 2 3 4 9 5 6 7 8 11 10 X23 1 2 X25 1 2 3 X26 1 2 3 X27 1 2 3 Ground RO3 RO3 RO3 RO2 RO2 RO2 RO1 RO1 RO1 +24 V GND DI1 DI2 DI3 DI4 DGND1 DI5 DI6 +24VD +24VD DIIL DGND2 VREF+ AGND AI1+ AI1AI2+ AI2AI3+ AI3AO1+ AO1AO2+ AO2VREFAGND
(Test voltage: 500 V AC)
Common mode voltage between channels 15 V
Jumper J1 settings: All digital inputs share a common ground. This is the default setting.
J1
or
Grounds of input groups DI1DI4 and DI5/DI6/DIIL are separate (insulation voltage 50 V).
(Test voltage: 4 kV AC)
72
73
Maintenance
This chapter contains preventive maintenance instructions.
Safety
WARNING! Read the Safety instructions on the first pages of this manual before performing any maintenance on the equipment. Ignoring the safety instructions can cause injury or death.
WARNING! The drive module is heavy [frame size R7: 100 kg (220 lb), frame size R8: 200 kg (441 lb)]. Lift the module by the upper part using the lifting lugs attached to the top of the unit. Do not tilt the drive module. The centre of gravity of the unit is high. The unit will overturn from a tilt of about 6 degrees. An overturning unit can cause physical injury.
0 Max 3
Do not tilt!
Maintenance
74
Maintenance intervals
If installed in an appropriate environment, the drive requires very little maintenance. This table lists the routine maintenance intervals recommended by ABB.
Interval Every year when stored Every 6 to 12 months (depending on the dustiness of the environment) Every 6 years Every 10 years Maintenance Capacitor reforming Heatsink temperature check and cleaning Cooling fan change Capacitor change Instruction See Reforming. See Heatsink.
See Fan. See Capacitors.
Maintenance
75
Layout
The layout stickers of the drive are shown below. The stickers show all possible components. Not all of them are present in each delivery or described here. Components that need to be changed regularly are listed below:
Designation Y41 C_ Cooling fan Capacitors Component
R7
R8
Code: 64572261
Code: 64601423
Maintenance
76
Heatsink
Check the cleanliness of the cabinet and the surroundings. When necessary, clean the interior of the cabinet with a soft brush and a vacuum cleaner. The module heatsink fins pick up dust from the cooling air. The drive runs into overtemperature warnings and faults if the heatsink is not clean. When necessary, contact ABB for cleaning of the heatsink.
Fan
The lifespan of the cooling fan of the drive module is about 50 000 hours. The actual lifespan depends on the running time of the fan, ambient temperature and dust concentration. See the appropriate ACS800 firmware manual for the actual signal which indicates the running time of the cooling fan. For resetting the running time signal after a fan replacement, please contact ABB. Replacement fans are available from ABB. Do not use other than ABB specified spare parts.
Maintenance
77
Replacing the fan (R7) 1. Remove the front cover. 2. Disconnect the discharging resistor wire(s). 3. Remove the DC capacitor pack by undoing the red fixing screws and pulling the pack out. 4. Disconnect the fan supply wires (detachable connector). 5. Disconnect the fan capacitor wires. 6. Disconnect the AINP board wires from connectors X1 and X2. 7. Undo the red fixing screws of the fan cassette. 8. Press the snap-on holders to release the side cover. 9. Lift the handle and pull the fan cassette out. 10. Install the new fan and fan capacitor in reverse order to the above.
3 3
4 7
2 pcs in 690 V units 9
7 3 3
3 DC-
DC+
Maintenance
78
Replacing the fan (R8) 1. Remove the front cover. 2. Disconnect the fan capacitor and power supply wires. 3. Undo the red fastening screws of the plastic side cover of the fan. Shift the cover to the right to free its right-hand edge and lift the cover off. 4. Undo the red fastening screws of the fan. 5. Lift the fan out of the cabinet. 6. Install the new fan and fan capacitor in reverse order to the above.
4 3 5
4 3
Maintenance
79
Capacitors
The drive intermediate circuit employs several electrolytic capacitors. Their lifespan is at least 90 000 hours depending on the operating time of the drive, loading and ambient temperature. Capacitor life can be prolonged by lowering the ambient temperature. It is not possible to predict a capacitor failure. Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. Contact ABB if capacitor failure is suspected. Replacements are available from ABB. Do not use other than ABB specified spare parts. Reforming Reform (re-age) spare part capacitors once a year according to ACS 600/800 Capacitor Reforming Guide [code: 64059629 (English)]. Replacing the capacitor pack (R7) Replace the capacitor pack as described in section Replacing the fan (R7).
Maintenance
80
Replacing the capacitor pack (R8) 1. Remove the front cover. Remove the profiled side plate. 2. Disconnect the discharging resistor wires. 3. Undo the fastening screws. 4. Lift the capacitor pack out. 5. Install the new capacitor pack in reverse order to the above.
At the rear side (view from below)
3 3 3 2
2 4 2 pcs in 690 V units
3 3 2 pcs M6x12 combi screw 3
M10
3 M6
Maintenance
81
Replacing the drive module

Disconnect the input power cable from the module. Disconnect the power supply cable and the fibre optic cables from the RMIO board and coil them on the top of the converter module. Disconnect the busbars outside the module. Undo the upper fastening screws of the module (if used). Disconnect the pedestal from the module by undoing the fastening (a) and busbar connecting (b) screws.
Frame size R7 b a a b b b b b a a a M6 combi screw Tightening torque: 5 Nm (3.7 lbf ft) b M8x25 combi screw Tightening torque: 15...22 Nm (11...16 lbf ft)
Frame size R8
a b b b b b
a M6x16 combi screws Tightening torque: 5 Nm (3.7 lbf ft)
b M10x25 combi screws Tightening torque: 30...44 Nm (22...32 lbf ft)
Secure the module from the lifting hooks at the top. Pull the module from the cabinet onto a pallet truck. Install the new module in reverse order to the above.
Maintenance
82
LEDs
This table describes LEDs of the drive.
Where RMIO board Red Green Control panel mounting platform Red Green AINT board V204 (green) V309 (red) V310 (green) LED Drive in fault state The power supply on the board is OK. Drive in fault state The main + 24 V power supply for the control panel and the RMIO board is OK. +5 V voltage of the board is OK. Prevention of unexpected start is ON. IGBT control signal transmission to the gate driver control boards is enabled. When the LED is lit
Maintenance
83
Technical data
This chapter contains the technical specifications of the drive, e.g. the ratings, sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings, and warranty policy.
IEC data
Ratings The IEC ratings for the ACS800-04 with 50 Hz and 60 Hz supplies are given below. The symbols are described below the table.
ACS800-04 size Nominal ratings Imax
Nooverload use
Pcont.max
Light-overload use Heavy-duty use I2hd A 170 202 240 4) 316 340 370 480 590 2) 635 3) 163 202 240 1) 340 370 477 590 2) 635 3) Phd kW 45 55 55 90 90 110 132 160 200 90 110 132 160 200 250 315 355
Frame size
Air flow
Heat dissipation
I2N PN kW A A kW Three-phase supply voltage 208 V, 220 V, 230 V or 240 V -0080-2 214 326 55 211 55 -0100-2 253 404 75 248 75 -0120-2 295 432 90 290 90 -0140-2 405 588 110 396 110 -0170-2 447 588 132 440 132 -0210-2 528 588 160 516 160 -0230-2 613 840 160 598 160 -0260-2 693 1017 200 679 200 -0300-2 720 1017 200 704 200 Three-phase supply voltage 380 V, 400 V or 415 V -0140-3 206 326 110 202 110 -0170-3 248 404 132 243 132 -0210-3 289 432 160 284 160 -0260-3 445 588 200 440 200 -0320-3 521 588 250 516 250 -0400-3 602 840 315 590 315 -0440-3 693 1017 355 679 355 -0490-3 720 1017 400 704 400
Icont.max
m3/h R7 R7 R7 R8 R8 R8 R8 R8 R8 R7 R7 R7 R8 R8 R8 R8 R8 540 540 540 1220 1220 1220 1220 1220 1220 540 540 540 1220 1220 1220 1220 1220 2900 3450 4050 5300 6100 6700 7600 7850 8300 3000 3650 4300 6600 7150 8100 8650 9100
Technical data
84
ACS800-04 size
Nominal ratings
Icont.max
Nooverload use
Light-overload use Heavy-duty use
Frame size
Air flow
Heat dissipation
Pcont.max I2N PN I2hd Phd kW A A kW A kW Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V -0170-5 196 326 132 192 132 162 110 -0210-5 245 384 160 240 160 192 132 -0260-5 289 432 200 284 200 224 160 -0320-5 440 588 250 435 250 340 200 -0400-5 515 588 315 510 315 370 250 -0440-5 550 840 355 545 355 490 315 -0490-5 602 840 400 590 400 515 2) 355 2) -0550-5 684 1017 450 670 450 590 400 450 -0610-5 718 1017 500 704 500 632 3) Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V -0140-7 134 190 132 125 110 95 90 -0170-7 166 263 160 155 132 131 110 -0210-7 166/203* 294 160 165/195* 160 147 132 -0260-7 175/230* 326 160/200* 175/212* 160/200* 163 160 -0320-7 315 433 315 290 250 216 200 -0400-7 353 548 355 344 315 274 250 -0440-7 396 656 400 387 355 328 315 -0490-7 445 775 450 426 400 387 355 -0550-7 488 853 500 482 450 426 400 -0610-7 560 964 560 537 500 482 450
Imax
m3/h R7 R7 R7 R8 R8 R8 R8 R8 R8 R7 R7 R7 R7 R8 R8 R8 R8 R8 R8 540 540 540 1220 1220 1220 1220 1220 1220 540 540 540 540 1220 1220 1220 1220 1220 1220 3000 3800 4500 6850 7800 7600 8100 9100 9700 2800 3550 4250 4800 6150 6650 7400 8450 8300 9750
PDM code: 00096931-G
1) 2)
50% overload is available for one minute every 5 minutes if ambient temperature is less than 25 C. If ambient temperature is 40 C, max. available overload is 37%. 50% overload is available for one minute every 5 minutes if ambient temperature is less than 30 C. If ambient temperature is 40 C, max. available overload is 40%. 50% overload is available one minute every 5 minutes if ambient temperature is less than 20 C. If ambient temperature is 40 C, max. available overload is 30%. 50% overload is available one minute every 5 minutes if ambient temperature is less than 35 C. If ambient temperature is 40 C, max. available overload is 45%. higher value applicable if output frequency is above 41 Hz
3)
4) *
Technical data
85
Symbols
Nominal ratings Icont.max continuous rms output current. No overload capability at 40 C. Imax maximum output current. Available for 10 s at start, otherwise as long as allowed by drive temperature. Typical ratings: No-overload use Pcont.max typical motor power. The power ratings apply to most IEC 34 motors at the nominal voltage, 230 V, 400 V, 500 V or 690 V. Light-overload use (10% overload capability) I2N continuous rms current. 10% overload is allowed for one minute every 5 minutes. typical motor power. The power ratings apply to most IEC 34 motors at the nominal voltage, PN 230 V, 400 V, 500 V or 690 V. Heavy-duty use (50% overload capability) I2hd continuous rms current. 50% overload is allowed for one minute every 5 minutes. Phd typical motor power. The power ratings apply to most IEC 34 motors at the nominal voltage, 230 V, 400 V, 500 V or 690 V.
Sizing
The current ratings are the same regardless of the supply voltage within one voltage range. To achieve the rated motor power given in the table, the rated current of the drive must be higher than or equal to the rated motor current. Note 1: The maximum allowed motor shaft power is limited to 1.5 Phd, 1.1 PN or Pcont.max (whichever value is greatest). If the limit is exceeded, motor torque and current are automatically restricted. The function protects the input bridge of the drive against overload. If the condition exists for 5 minutes, the limit is set to Pcont.max. Note 2: The ratings apply at ambient temperature of 40 C (104 F). In lower temperatures the ratings are higher (except Imax). Note 3: Use the DriveSize PC tool for a more accurate dimensioning if the ambient temperature is below 40 C (104 F) or the drive is loaded cyclically.
Derating
The load capacity (current and power) decreases if the installation site altitude exceeds 1000 metres (3281 ft), or if the ambient temperature exceeds 40 C (104 F). Note: If the ingoing cooling air temperature of the drive module is max. 40 C (104 F), no derating of the drive output current is needed despite the cabinet temperature rising over 40 C (104 F). Temperature derating In the temperature range of +40 C (+104 F) to +50 C (+122 F), the rated output current is decreased by 1% for every additional 1 C (1.8 F). The output current is calculated by multiplying the current given in the rating table by the derating factor. Example If the ambient temperature is 50 C (+122 F), the derating factor is 100% - 1 % 10 C = C or 0.90 I . 90% or 0.90. The output current is then 0.90 I , 0.90 I
2N 2hd cont.max
Altitude derating At altitudes from 1000 to 4000 m (3281 to 13123 ft) above sea level, the derating is 1% for every 100 m (328 ft). For a more accurate derating, use the DriveSize PC tool. See Installation sites above 2000 metres (6562 feet) on page 52.
Technical data
86
Fuses gG and aR fuses for protection against short-circuit in the input power cable or drive are listed below. Either fuse type may be used if it operates rapidly enough. Choose between gG and aR fuses according to the table under Quick guide for selecting between gG and aR fuses on page 91, or verify the operating time by checking that the short-circuit current of the installation is at least the value given in the fuse table. The short-circuit current can be calculated as follows: Ik2-ph = 2 where Ik2-ph = short-circuit current in symmetrical two-phase short-circuit (A) U = network line-to-line voltage (V) Rc = cable resistance (ohm) Zk = zk UN2/SN = transformer impedance (ohm) zk = transformer impedance (%) UN = transformer rated voltage (V) SN = nominal apparent power of the transformer (kVA) Xc = cable reactance (ohm). Calculation example
Drive: ACS800-04-0260-3 supply voltage U = 410 V rated power SN = 3000 kVA rated voltage UN = 430 V transformer impedance zk = 7.2%. length = 170 m resistance/length = 0.112 ohm/km reactance/length = 0.0273 ohm/km. UN2 (430 V)2 = 4.438 mohm = 0.072 SN 3000 kVA
U Rc2 + (Zk + Xc)2
Transformer:
Supply cable:
Zk = zk
Technical data
87
Rc = 170 m 0.112
ohm = 19.04 mohm km
Xc = 170 m 0.0273
ohm = 4.641 mohm km
Ik2-ph
410 V 2 (19.04 mohm)2 + (4.438 mohm + 4.641 mohm)2
= 9.7 kA
The calculated short-circuit current 9.7 kA is higher than the minimum short-circuit current of the drive gG fuse type OFAF3H500 (8280 A). -> The 500 V gG fuse (ABB Control OFAF3H500) can be used.
Fuse tables gG fuses

ACS800-04 size Min. shortcircuit current 1) A A A A2s Three-phase supply voltage 208 V, 220 V, 230 V or 240 V -0080-2 201 3820 250 550 000 -0100-2 239 4510 315 1 100 000 -0120-2 285 4510 315 1 100 000 -0140-2 391 8280 500 2 900 000 -0170-2 428 8280 500 2 900 000 -0210-2 506 10200 630 4 000 000 -0230-2 599 10200 630 4 000 000 -0260-2 677 13500 800 7 400 000 -0300-2 707 13500 800 7 400 000 Three-phase supply voltage 380 V, 400 V or 415 V -0140-3 196 3820 250 550 000 -0170-3 237 4510 315 1 100 000 -0210-3 286 4510 315 1 100 000 -0260-3 438 8280 500 2 900 000 -0320-3 501 10200 630 4 000 000 -0400-3 581 10200 630 4 000 000 -0440-3 674 13500 800 7 400 000 -0490-3 705 13500 800 7 400 000 Input current Fuse
V 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500
Manufacturer ABB Control ABB Control ABB Control ABB Control ABB Control ABB Control ABB Control ABB Control ABB Control ABB Control ABB Control ABB Control ABB Control ABB Control ABB Control ABB Control ABB Control
Type OFAF1H250 OFAF2H315 OFAF2H315 OFAF3H500 OFAF3H500 OFAF3H630 OFAF3H630 OFAF3H800 OFAF3H800 OFAF1H250 OFAF2H315 OFAF2H315 OFAF3H500 OFAF3H630 OFAF3H630 OFAF3H800 OFAF3H800
IEC size 1 2 2 3 3 3 3 3 3 1 2 2 3 3 3 3 3
Technical data
88
gG fuses
Min. shortFuse circuit current 1) A A A A2s V Manufacturer Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V -0170-5 191 3820 250 550 000 500 ABB Control -0210-5 243 4510 315 1 100 000 500 ABB Control -0260-5 291 4510 315 1 100 000 500 ABB Control -0320-5 424 8280 500 2 900 000 500 ABB Control -0400-5 498 10200 630 4 000 000 500 ABB Control -0440-5 543 10200 630 4 000 000 500 ABB Control -0490-5 590 10200 630 4 000 000 500 ABB Control -0550-5 669 13500 800 7 400 000 500 ABB Control -0610-5 702 13500 800 7 400 000 500 ABB Control Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V -0140-7 126 2400 160 220 000 690 ABB Control -0170-7 156 2850 200 350 000 690 ABB Control -0210-7 191 3820 250 700 000 690 ABB Control -0260-7 217 3820 250 700 000 690 ABB Control -0320-7 298 4510 315 820 000 690 ABB Control -0400-7 333 6180 400 1 300 000 690 ABB Control -0440-7 377 8280 500 3 800 000 690 ABB Control -0490-7 423 8280 500 3 800 000 690 ABB Control -0550-7 468 8280 500 3 800 000 690 ABB Control -0610-7 533 10800 630 10 000 000 690 Bussmann ** rated breaking capacity only up to 50 kA
1)
ACS800-04 size
Input current
Type OFAF1H250 OFAF2H315 OFAF2H315 OFAF3H500 OFAF3H630 OFAF3H630 OFAF3H630 OFAF3H800 OFAF3H800 OFAA1GG160 OFAA1GG200 OFAA2GG250 OFAA2GG250 OFAA2GG315 OFAA3GG400 OFAA3H500 OFAA3H500 OFAA3H500 630NH3G-690 **
IEC size 1 2 2 3 3 3 3 3 3 1 1 2 2 2 3 3 3 3 3
minimum short-circuit current of the installation
Note 1: See also Planning the electrical installation: Thermal overload and short-circuit protection. For UL recognized fuses, see NEMA data on page 94. Note 2: In multicable installations, install only one fuse per phase (not one fuse per conductor). Note 3: Larger fuses than the recommended ones must not be used. Note 4: Fuses from other manufacturers can be used if they meet the ratings and the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table.
PDM code: 00096931-G, 00556489 A
Technical data
89
Ultrarapid (aR) fuses

ACS800-04 size Input current A Min. shortcircuit current 1) A A A2s V Fuse
Manufacturer
Type DIN 43620
Size
Three-phase supply voltage 208 V, 220 V, 230 V or 240 V -0080-2 -0100-2 -0120-2 -0140-2 -0170-2 -0210-2 -0230-2 -0260-2 -0300-2 -0140-3 -0170-3 -0210-3 -0260-3 -0320-3 -0400-3 -0440-3 -0490-3 -0170-5 -0210-5 -0260-5 -0320-5 -0400-5 -0440-5 -0490-5 -0550-5 -0610-5 -0140-7 -0170-7 -0210-7 -0260-7 -0320-7 -0400-7 -0440-7 -0490-7 -0550-7 -0610-7 201 239 285 391 428 506 599 677 707 196 237 286 438 501 581 674 705 191 243 291 424 498 543 590 669 702 126 156 191 217 298 333 377 423 468 533 1810 2210 2620 4000 4000 5550 7800 8850 8850 1810 2210 2620 4000 5550 7800 8850 8850 1810 2210 2620 4000 5550 7800 7800 8850 8850 1520 1520 1610 1610 3010 2650 4000 4790 4790 5550 400 500 550 800 800 1000 1250 1400 1400 400 500 550 800 1000 1250 1400 1400 400 500 550 800 1000 1250 1250 1400 1400 350 350 400 400 630 630 800 900 900 1000 105 000 145 000 190 000 465 000 465 000 945 000 1 950 000 3 900 000 3 900 000 105 000 145 000 190 000 465 000 945 000 1 950 000 3 900 000 3 900 000 105 000 145 000 190 000 465 000 945 000 1 950 000 1 950 000 3 900 000 3 900 000 68 500 68 500 74 000 74 000 275 000 210 000 465 000 670 000 670 000 945 000 690 690 690 690 690 690 690 690 690 690 690 690 690 690 690 690 690 690 690 690 690 690 690 690 690 690 690 690 690 690 690 690 690 690 690 690 Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann 170M3819 170M5810 170M5811 170M6812 170M6812 170M6814 170M8554 170M8555 170M8555 170M3819 170M5810 170M5811 170M6812 170M6814 170M8554 170M8555 170M8555 170M3819 170M5810 170M5811 170M6812 170M6814 170M8554 170M8554 170M8555 170M8555 170M3818 170M3818 170M5808 170M5808 170M5812 170M6810 170M6812 170M6813 170M6813 170M6814 DIN1* DIN2* DIN2* DIN3 DIN3 DIN3 DIN3 DIN3 DIN3 DIN1* DIN2* DIN2* DIN3 DIN3 DIN3 DIN3 DIN3 DIN1* DIN2* DIN2* DIN2* DIN3 DIN3 DIN3 DIN3 DIN3 DIN1* DIN1* DIN2* DIN2* DIN2* DIN3 DIN3 DIN3 DIN3 DIN3
Three-phase supply voltage 380 V, 400 V or 415 V
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V
Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V
Technical data
90
Ultrarapid (aR) fuses

ACS800-04 size Input current A Min. shortcircuit current 1) A A A2s V Fuse
Manufacturer
Type DIN 43620
Size
A2s value for -7 units at 660 V

1)
minimum short-circuit current of the installation
Note 1: See also Planning the electrical installation: Thermal overload and short-circuit protection. For UL recognized fuses, see NEMA data on page 94. Note 2: In multicable installations, install only one fuse per phase (not one fuse per conductor). Note 3: Larger fuses than the recommended ones must not be used. Note 4: Fuses from other manufacturers can be used if they meet the ratings and the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table.
PDM code: 00096931-G, 00556489 A
Technical data
91
Quick guide for selecting between gG and aR fuses The table below is a short cut in selecting between gG and aR fuses. The combinations (cable size, cable length, transformer size and fuse type) in the table fulfil the minimum requirements for the proper operation of the fuse.
ACS800-04 size Cable type Copper Aluminium 10 m Three-phase supply voltage 208 V, 220 V, 230 V or 240 V -0080-2 -0100-2 -0120-2 -0140-2 -0170-2 -0210-2 -0230-2 -0260-2 -0300-2 -0140-3 -0170-3 -0210-3 -0260-3 -0320-3 -0400-3 -0440-3 -0490-3 -0170-5 -0210-5 -0260-5 -0320-5 -0400-5 -0440-5 -0490-5 -0550-5 -0610-5 -0140-7 -0170-7 -0210-7 -0260-7 -0320-7 -0400-7 -0440-7 -0490-7 -0550-7 -0610-7 3120 Cu 3150 Cu 3240 Cu 3185 Al 3240 Al 2 (395) Al 120 140 140 250 250 310 310 410 410 200 240 240 430 530 530 700 700 250 290 290 530 660 660 660 880 880 220 260 340 340 400 550 730 730 730 960 150 170 170 320 320 400 400 510 510 220 260 260 460 600 600 770 770 270 320 320 570 720 720 720 980 980 220 260 360 360 410 570 780 780 780 1000 260 310 310 560 750 750 930 930 310 360 360 670 840 840 840 1200 1200 240 280 390 390 430 610 860 860 860 1100 81 96 120 160 180 210 240 270 290 160 170 200 310 350 410 470 490 200 220 260 370 440 500 520 580 610 160 190 230 260 360 400 460 510 560 640 81 96 120 160 180 230 340 380 380 160 170 200 310 350 470 530 530 200 220 260 370 440 570 570 670 670 160 190 230 260 360 400 460 510 560 640 160 170 200 310 440 660 730 730 200 220 260 370 480 760 760 880 880 160 190 230 260 360 400 460 510 560 640
PDM code: 00556489 A
Supply transformer minimum apparent power SN (kVA) Maximum cable length with gG fuses 50 m 100 m Maximum cable length with aR fuses 10 m 100 m 200 m
2 (3120) Cu 3 (395) Al 2 (3120) Cu 3 (395) Al 3 (395) Cu 2 (3240) Al 3 (3120) Cu 3 (3185) Al 3 (3150) Cu 3 (3240) Al 3 (3150) Cu 3 (3240) Al 3120 Cu 3150 Cu 3240 Cu 3 (370) Cu 3 (395) Cu 3185 Al 3240 Al 2 (3120) Al 3 (3120) Al 2 (3240) Al
Three-phase supply voltage 380 V, 400 V or 415 V
3 (3120) Cu 3 (3185) Al 3 (3150) Cu 3 (3240) Al 3 (3150) Cu 3 (3240) Al 3120 Cu 3150 Cu 3240 Cu 3150 Al 3240 Al 2 (3120) Al
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V
2 (3120) Cu 3 (395) Al 2 (3150) Cu 2 (3240) Al 3 (395) Cu 3 (3150) Al 3 (3120) Cu 3 (3185) Al 2 (3240) Cu 3 (3240) Al 3 (3150) Cu 3 (3240) Al 370 Cu 395 Cu 3120 Cu 3150 Cu 3240 Cu 3240 Cu 395 Al 3120 Al 3150 Al 3185 Al 2 (3120) Al 3 x (370) Al
Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V
2 (3120) Cu 2 (3150) Al 2 (3120) Cu 3 (395) Al 2 (3150) Cu 3 (3120) Al 3 (395) Cu 3 (3150) Al
Note 1: The supply transformer minimum power in kVA is calculated with a zk value of 6% and frequency 50 Hz.
Technical data
92
Note 2: The table is not intended for transformer selection - that must be done separately. The following parameters can effect on the correct operation of the protection: cable length, i.e. the longer the cable the weaker the fuse protection, as the long cable limits the fault current cable size, i.e. the smaller the cable cross-section the weaker the fuse protection, as the small cable size limits the fault current transformer size, i.e the smaller the transformer the weaker the fuse protection, as the small transformer limits the fault current transformer impedance, i.e. the higher the zk the weaker the fuse protection as high impedance limits the fault current.
The protection can be improved by installing a larger supply transformer and/or bigger cables, and in most cases by selecting aR fuses instead of gG fuses. Selection of smaller fuses improves the protection, but may also affect the fuse life time and lead to unnecessary operation of the fuses. In case of any uncertainty regarding the drive protection, please contact your local ABB.
Cable types The table below gives copper and aluminium cable types for different load currents. Cable sizing is based on max. 9 cables laid on a cable ladder side by side, ambient temperature 30 C, PVC insulation, surface temperature 70 C (EN 60204-1 and IEC 60364-5-52/2001). For other conditions, size the cables according to local safety regulations, appropriate input voltage and the load current of the drive.
Copper cables with concentric copper shield Max. load current A 56 71 88 107 137 167 193 223 255 301 274 334 386 446 510 602 579 669 765 903 Cable type mm2 316 325 335 350 370 395 3120 3150 3185 3240 2 (370) 2 (395) 2 (3120) 2 (3150) 2 (3x185) 2 (3240) 3 (3120) 3 (3150) 3 (3185) 3 (3240)
3BFA 01051905 C
Aluminium cables with concentric copper shield Max. load current A 69 83 107 130 151 174 199 235 214 260 302 348 398 470 522 597 705 Cable type mm2 335 350 370 395 3120 3150 3185 3240 2 (370) 2 (395) 2 (3120) 2 (3150) 2 (3185) 2 (3240) 3 (3150) 3 (3185) 3 (3240)
Technical data
93
Cable entries Mains, motor and brake resistor cable terminal sizes (per phase), maximum accepted cable and tightening torques are given below.
Frame size U1, V1, W1, U2, V2, W2, UDC+/R+, UDC-, RNumber of holes per Max. cable Screw Tightening phase torque Nm mm2 3 1240 or M12 50...75 2185 3 3240 M12 50...75 Earthing PE Screw Tightening torque Nm 30...44 30...44
R7 R8
M10 M10
Dimensions, weights and noise

Frame size Busbars on the long side (bookshelf) H W1 W2 D mm mm mm mm 1121 334 427 473 1564 415 562 568 H height IP 00 Busbars on the short side (flat) H mm 1181 1596 W3 mm 525 607 W4 mm 631 779 D mm 259 403 Weight Noise
R7 R8
kg 100 200
dB 71 72
W1 width of the basic unit with PE terminal (bookshelf) W2 width with the cable connection terminal plates on the left side only (bookshelf) (R7: width with the cable connection terminal plates on both sides is 579 mm) (R8: width with the cable connection terminal plates on both sides is 776 mm) D depth without fastening brackets (R7 bookshelf: depth with fastening brackets is 516 mm) (R8 bookshelf: depth with fastening brackets is 571 mm)
W3 width of the basic unit with PE terminal/busbar (flat) W4 width with the cable connection terminal plates (flat)
Frame size
R7 H W D *
IP 00, with bottom exit H W D mm mm mm 1126 264 471
Weight * kg 91
height without top and bottom exit busbar shrouds width depth weight without top entry and bottom exit shrouds
Technical data
94
NEMA data
Ratings The NEMA ratings for the ACS800-U4 and ACS800-04 with 60 Hz supplies are given below. The symbols are described below the table. For sizing, derating and 50 Hz supplies, see IEC data.
ACS800-U4 size ACS800-04 size Imax Normal use Heavy-duty use Phd HP 60 75 75 125 125 150 200 200 250 125 150 150 200 250 250 300 400 450 500 500 100 2) 125 150 150 200 250 350 2) 400 450 500 R7 R7 R7 R8 R8 R8 R8 R8 R8 R7 R7 R7 R8 R8 R8 R8 R8 R8 R8 R8 R7 R7 R7 R7 R8 R8 R8 R8 R8 R8 Frame size Air flow Heat dissipation BTU/Hr 9900 11750 13750 18100 20800 22750 25900 26750 28300 10100 12900 15300 15350 18050 23250 26650 25950 27600 31100 33000 9600 12150 14550 16400 21050 22750 25300 28900 28350 33300
I2N PN I2hd A A HP A Three-phase supply voltage 208 V, 220 V, 230 V, 240 V -0080-2 326 211 75 170 -0100-2 404 248 100 202 -0120-2 432 290 100 240 4) -0140-2 588 396 150 316 -0170-2 588 440 150 340 -0210-2 588 516 200 370 -0230-2 840 598 200 480 -0260-2 1017 679 250 590 3) -0300-2 1017 704 250 635 3) Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V -0170-5 326 192 150 162 -0210-5 384 240 200 192 1) 2) -0260-5 432 289 250 224 -0270-5 ** 480 316 250 240 -0300-5 ** 568 361 300 302 -0320-5 588 435 350 340 -0400-5 588 510 400 370 -0440-5 840 545 450 490 -0490-5 840 590 500 515 3) -0550-5 1017 670 550 590 3) -0610-5 1017 718 4) 600 590 3) Three-phase supply voltage 525 V, 575 V or 600 V -0140-7 190 125 125 95 -0170-7 263 155 150 131 -0210-7 294 165/195* 150/200* 147 -0260-7 326 175/212* 150/200* 163 -0320-7 433 290 300 216 -0400-7 548 344 350 274 -0440-7 656 387 400 328 -0490-7 775 426 450 387 -0550-7 853 482 500 426 -0610-7 964 537 500 482
1)
ft3/min 318 318 318 718 718 718 718 718 718 318 318 318 718 718 718 718 718 718 718 718 318 318 318 318 718 718 718 718 718 718
available if ambient temperature is less than 30 C (86 F). If ambient temperature is 40 C (104 F), I2N is 286 A. special 4-pole high-efficiency NEMA motor
2)
Technical data
95
3) 4)
50% overload is allowed for one minute every five minutes if ambient temperature is less than 30 C (86 F). 40% overload is allowed if ambient temperature is 40 C (104 F). available if ambient temperature is less than 30 C (86 F). If ambient temperature is 40 C (104 F), I2N is 704 A. higher value available if output frequency is above 41 Hz ACS800-U4 types only
* **
Symbols
Imax maximum output current. Available for 10 s at start, otherwise as long as allowed by drive temperature. Normal use (10% overload capability) I2N continuous rms current. 10% overload is typically allowed for one minute every 5 minutes. typical motor power. The power ratings apply to most 4-pole NEMA rated motors (230 V, PN 460 V or 575 V). Heavy-duty use (50% overload capability) I2hd continuous rms current. 50% overload is typically allowed for one minute every 5 minutes. Phd typical motor power. The power ratings apply to most 4-pole NEMA rated motors (230 V, 460 V or 575 V). Note: The ratings apply at ambient temperature of 40 C (104 F). At lower temperatures the ratings are higher.
Sizing See page 85. Derating See page 85. Fuses UL class T or L fuses for branch circuit protection per NEC are listed below. Fast acting class T or faster fuses are recommended in the USA. Check from the fuse time-current curve that the operating time of the fuse is below 0.1 seconds. The operating time depends on the supply network impedance and the cross-sectional area and length of the supply cable. The short-circuit current can be calculated as shown on page 86.
Technical data
96
UL class T and L fuses

Input Fuse current A A V Manufacturer Type UL class Three-phase supply voltage 208 V, 220 V, 230 V, 240 V -0080-2 201 250 600 Bussmann JJS-250 T -0100-2 239 300 600 Bussmann JJS-300 T -0120-2 285 400 600 Bussmann JJS-400 T -0140-2 391 500 600 Bussmann JJS-500 T -0170-2 428 600 600 Bussmann JJS-600 T -0210-2 506 600 600 Bussmann JJS-600 T -0230-2 599 800 600 Ferraz A4BY800 L -0260-2 677 800 600 Ferraz A4BY800 L -0300-2 707 900 600 Ferraz A4BY900 L Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V -0170-5 175 250 600 Bussmann JJS-250 T -0210-5 220 300 600 Bussmann JJS-300 T -0260-5 267 400 600 Bussmann JJS-400 T -0270-5 293 500 600 Bussmann JJS-500 T -0300-5 331 500 600 Bussmann JJS-500 T -0320-5 397 500 600 Bussmann JJS-500 T -0400-5 467 600 600 Bussmann JJS-600 T -0440-5 501 800 600 Ferraz A4BY800 L -0490-5 542 800 600 Ferraz A4BY800 L -0550-5 614 900 600 Ferraz A4BY900 L -0610-5 661 900 600 Ferraz A4BY900 L Three-phase supply voltage 525 V, 575 V or 600 V -0140-7 117 200 600 Bussmann JJS-200 T -0170-7 146 200 600 Bussmann JJS-200 T -0210-7 184 250 600 Bussmann JJS-250 T -0260-7 199 300 600 Bussmann JJS-300 T -0320-7 273 500 600 Bussmann JJS-500 T -0400-7 325 500 600 Bussmann JJS-500 T -0440-7 370 500 600 Bussmann JJS-500 T -0490-7 407 600 600 Bussmann JJS-600 T -0550-7 463 600 600 Bussmann JJS-600 T -0610-7 513 700 600 Ferraz A4BY700 L Note 1: See also Planning the electrical installation: Thermal overload and short-circuit protection. Note 2: In multicable installations, install only one fuse per phase (not one fuse per conductor). Note 3: Larger fuses than the recommended ones must not be used. Note 4: Fuses from other manufacturers can be used if they meet the ratings and the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table.
ACS800-U4 type
Technical data
97
Cable types
Cable sizing is based on NEC Table 310-16 for copper wires, 75 C (167 F) wire insulation at 40 C (104 F) ambient temperature. Not more than three current-carrying conductors in raceway or cable or earth (directly buried). For other conditions, dimension the cables according to local safety regulations, appropriate input voltage and the load current of the drive.
Copper cables with concentric copper shield Max. load current A 57 75 88 101 114 132 154 176 202 224 251 273 295 334 370 405 449 502 546 590 669 739 810 884 1003 1109 1214 Cable type AWG/kcmil 6 4 3 2 1 1/0 2/0 3/0 4/0 250 MCM or 2 1 300 MCM or 2 1/0 350 MCM or 2 2/0 400 MCM or 2 2/0 500 MCM or 2 3/0 600 MCM or 2 4/0 or 3 1/0 700 MCM or 2 4/0 or 3 2/0 2 250 MCM or 3 2/0 2 300 MCM or 3 3/0 2 350 MCM or 3 4/0 2 400 MCM or 3 4/0 2 500 MCM or 3 250 MCM 2 600 MCM or 3 300 MCM 2 700 MCM or 3 350 MCM 3 400 MCM or 4 250 MCM 3 500 MCM or 4 300 MCM 3 600 MCM or 4 400 MCM 3 700 MCM or 4 500 MCM
Cable Entries Input, motor and brake resistor cable terminal sizes (per phase) and tightening torques are given below. Two-hole 1/2 inch diameter cable lugs can be used.
Frame size R7 R8 Max. cable kcmil/AWG 2 250 MCM 3 700 MCM U1, V1, W1, U2, V2, W2, UDC+/R+, UDC-, R- Earthing PE Screw Tightening torque Screw lbf ft 1/2 37...55 3/8 1/2 37...55 3/8 Tightening torque lbf ft 22...32 22...32
Technical data
98
Dimensions, weights and noise

Frame size Height in. 44.13 61.57 H height UL type: open chassis W1 W2 in. in. 13.15 16.36 16.35 22.14 Weight Depth in. 18.31 22.36 lb 220 441 Noise dB 71 72
R7 R8
W1 width of the basic unit with PE terminal (bookshelf) W2 width with the cable connection terminal plates on the left side only (bookshelf) D depth without fastening brackets (R7 bookshelf: depth with fastening brackets is 20.32 in.) (R8 bookshelf: depth with fastening brackets is 22.48 mm)
Technical data
99
Input power connection

Voltage (U1) 208/220/230/240 VAC 3-phase 10% for 230 VAC units 380/400/415 VAC 3-phase 10% for 400 VAC units 380/400/415/440/460/480/500 VAC 3-phase 10% for 500 VAC units Rated conditional shortcircuit current (IEC 60439-1) Short-circuit current protection (UL 508C, CSA C22.2 No. 14-05) Frequency Imbalance Fundamental power factor (cos phi1) 525/550/575/600/660/690 VAC 3-phase 10% for 690 VAC units 65 kA when protected by fuses given in the fuse tables US and Canada: The drive is suitable for use on a circuit capable of delivering not more than 100 kA symmetrical amperes (rms) at 600 V maximum when protected by fuses given in the NEMA data fuse table. 48 to 63 Hz, maximum rate of change 17%/s Max. 3% of nominal phase to phase input voltage 0.98 (at nominal load)
Motor connection
Voltage (U2) Frequency 0 to U1, 3-phase symmetrical, Umax at the field weakening point DTC mode: 0 to 3.2 fFWP. Maximum frequency 300 Hz (120 Hz with du/dt or sine filter). fFWP = UNmains UNmotor fNmotor
Frequency resolution Current Power limit Field weakening point Switching frequency Maximum recommended motor cable length
fFWP: frequency at field weakening point; UNmains: mains (input power) voltage; UNmotor: rated motor voltage; fNmotor: rated motor frequency 0.01 Hz See section IEC data. 1.5 Phd, 1.1 PN or Pcont.max (whichever value is greatest) 8 to 300 Hz 3 kHz (average). In 690 V units 2 kHz (average).
Type code (EMC equipment) DTC control +E202 *, +E210 * 300 m (984 ft) 100 m (328 ft) Max. motor cable length Scalar control 300 m (984 ft) 100 m (328 ft)
* Motor cable longer than 100 m (328 ft) is allowed but then the EMC Directive requirements may not be fulfilled.
Efficiency
Approximately 98% at nominal power level
Cooling
Method Free space around the unit Cooling air flow Internal fan, flow direction from front to top Refer to ACS800-04/04M/U4 Cabinet Installation [68360323 (English)]. See IEC data.
Degrees of protection
IP 00 (UL type: open chassis)
Technical data
100
Prevention of Unexpected Start: AGPS-21 board

Nominal input voltage Input voltage range (selected by jumper) Nominal frequency Current Max. external fuse Input connector X1 User connector 1, 2, 3 Output voltage Nominal output current X2 terminal block type Ambient temperature Relative humidity Approvals 115 VAC or 230 VAC 95...132 VAC (X3 on), 185...265 VAC (X4 on, default) 50/60 Hz 0.77 A at 115 V, 0.44 A at 230 V 16 A 3 2.5 mm2 600 V, 25 A, 0.5...4 mm2 (20...12 AWG) 24 V + 0.5 V 1.7 A (50 C, 122 F) JST B3P-VH 0...50 C (32...122 F) 30...90%, no condensation allowed CE, C-UL US listed
Ambient conditions
Environmental limits for the drive are given below. The drive is to be used in a heated, indoor, controlled environment. Operation Storage Transportation installed for stationary use in the protective package in the protective package Installation site altitude 0 to 4000 m (13123 ft) above sea level [above 1000 m (3281 ft), see section Derating] -40 to +70 C (-40 to Air temperature -15 to +50 C (5 to 122 F). -40 to +70 C (-40 to No frost allowed. See +158 F) +158 F) section Derating. Relative humidity 5 to 95% Max. 95% Max. 95% No condensation allowed. Maximum allowed relative humidity is 60% in the presence of corrosive gases. Contamination levels No conductive dust allowed. (IEC 60721-3-3, IEC 60721-3- Boards without coating: Boards without coating: Boards without coating: 2, IEC 60721-3-1) Chemical gases: Class 3C1 Chemical gases: Class 1C2 Chemical gases: Class 2C2 Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2 Boards with coating: Chemical gases: Class 3C2 Solid particles: Class 3S2 70 to 106 kPa 0.7 to 1.05 atmospheres Max. 1 mm (0.04 in.) (5 to 13.2 Hz), max. 7 m/s2 (23 ft/s2) (13.2 to 100 Hz) sinusoidal Not allowed Not allowed Boards with coating: Chemical gases: Class 1C2 Solid particles: Class 1S3 70 to 106 kPa 0.7 to 1.05 atmospheres Max. 1 mm (0.04 in.) (5 to 13.2 Hz), max. 7 m/s2 (23 ft/s2) (13.2 to 100 Hz) sinusoidal Max. 100 m/s2 (330 ft./s2), 11 ms 100 mm (4 in.) for weight over 100 kg (220 lb) Boards with coating: Chemical gases: Class 2C2 Solid particles: Class 2S2 60 to 106 kPa 0.6 to 1.05 atmospheres Max. 3.5 mm (0.14 in.) (2 to 9 Hz), max. 15 m/s2 (49 ft/s2) (9 to 200 Hz) sinusoidal Max. 100 m/s2 (330 ft./s2), 11 ms 100 mm (4 in.) for weight over 100 kg (220 lb)
Atmospheric pressure Vibration (IEC 60068-2)
Shock (IEC 60068-2-29) Free fall
Technical data
101
Materials
Drive enclosure PC/ABS 2.5 mm, colour NCS 1502-Y (RAL 90021 / PMS 420 C) hot-dip zinc coated steel sheet 1.5 to 2.5 mm, thickness of coating 100 micrometres, colour NCS 1502-Y Plywood and wood. Plastic covering of the package: PE-LD, bands PP or steel. The drive contains raw materials that should be recycled to preserve energy and natural resources. The package materials are environmentally compatible and recyclable. All metal parts can be recycled. The plastic parts can either be recycled or burned under controlled circumstances, according to local regulations. Most recyclable parts are marked with recycling marks. If recycling is not feasible, all parts excluding electrolytic capacitors and printed circuit boards can be landfilled. The DC capacitors (C1-1 to C1-x) contain electrolyte and the printed circuit boards contain lead, both of which are classified as hazardous waste within the EU. They must be removed and handled according to local regulations. For further information on environmental aspects and more detailed recycling instructions, please contact your local ABB distributor.
Package Disposal
Applicable standards
EN 61800-5-1 (2003) EN 60204-1 (2006) The drive complies with the following standards. The compliance with the European Low Voltage Directive is verified according to standards EN 61800-5-1 and EN 60204-1. Adjustable speed electrical power drive systems. Part 5-1: Safety requirements electrical, thermal and energy Safety of machinery. Electrical equipment of machines. Part 1: General requirements. Provisions for compliance: The final assembler of the machine is responsible for installing - an emergency-stop device - a supply disconnecting device - the ACS800-04/04M/U4 into a cabinet. Degrees of protection provided by enclosures (IP code) Insulation coordination for equipment within low-voltage systems. Part 1: Principles, requirements and tests. Adjustable speed electrical power drive systems. Part 3: EMC requirements and specific test methods UL Standard for Safety, Power Conversion Equipment, second edition Industrial control equipment
EN 60529: 1991 (IEC 529) IEC 60664-1 (2007) EN 61800-3 (2004) UL 508C (2002) CSA C22.2 No. 14-05
US patents
This product is protected by one or more of the following US patents: 4,920,306 5,612,604 6,094,364 6,252,436 6,370,049 6,741,059 6,940,253 6,977,449 7,034,510 7,082,374 D510,320 5,301,085 5,654,624 6,147,887 6,265,724 6,396,236 6,774,758 6,934,169 6,984,958 7,036,223 7,084,604 D511,137 5,463,302 5,799,805 6,175,256 6,305,464 6,448,735 6,844,794 6,956,352 6,985,371 7,045,987 7,098,623 D511,150 5,521,483 5,940,286 6,184,740 6,313,599 6,498,452 6,856,502 6,958,923 6,992,908 7,057,908 7,102,325 D512,026 5,532,568 5,942,874 6,195,274 6,316,896 6,552,510 6,859,374 6,967,453 6,999,329 7,059,390 D503,931 D512,696 5,589,754 5,952,613 6,229,356 6,335,607 6,597,148 6,922,883 6,972,976 7,023,160 7,067,997 D510,319 D521,466.
Technical data
102
CE marking
A CE mark is attached to the drive to verify that the unit follows the provisions of the European Low Voltage and EMC Directives (Directive 73/23/EEC, as amended by 93/68/EEC and Directive 89/336/ EEC, as amended by 2004/108EC).
Definitions
EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to operate without problems within an electromagnetic environment. Likewise, the equipment must not disturb or interfere with any other product or system within its locality. First environment includes establishments connected to a low-voltage network which supplies buildings used for domestic purposes. Second environment includes establishments connected to a network not supplying domestic premises. Drive of category C2: drive of rated voltage less than 1000 V and intended to be installed and commissioned only by a professional when used in the first environment. Note: A professional is a person or organisation having necessary skills in installing and/or commissioning power drive systems, including their EMC aspects. Drive of category C3: drive of rated voltage less than 1000 V and intended for use in the second environment and not intended for use in the first environment. Drive of category C4: drive of rated voltage equal to or above 1000 V, or rated current equal to or above 400 A, or intended for use in complex systems in the second environment.
Compliance with the EMC Directive

The EMC Directive defines the requirements for immunity and emissions of electrical equipment used within the European Union. The EMC product standard [EN 61800-3 (2004)] covers requirements stated for drives.
Compliance with the EN 61800-3 First environment (drive of category C2)

The drive complies with the standard with the following provisions: 1. The drive is equipped with EMC filter +E202. 2. The motor and control cables are selected as specified in the Hardware Manual. 3. The drive is installed according to the instructions given in the Hardware Manual. 4. Maximum cable length is 100 metres. WARNING! The drive may cause radio interference if used in a residential or domestic environment. The user is required to take measures to prevent interference, in addition to the requirements for CE compliance listed above, if necessary. Note: It is not allowed to install a drive equipped with the EMC filter +E202 on IT (unearthed) systems. The supply network becomes connected to earth potential through the EMC filter capacitors which may cause danger or damage the unit.
Technical data
103
Second environment (drive of category C3)

The drive complies with the standard with the following provisions: 1. The drive is equipped with EMC filter +E210. The filter is suitable for TN (earthed) and IT (unearthed) systems. 2. The motor and control cables are selected as specified in the Hardware Manual. 3. The drive is installed according to the instructions given in the Hardware Manual. 4. Maximum cable length is 100 metres. WARNING! A drive of category C3 is not intended to be used on a low-voltage public network which supplies domestic premises. Radio frequency interference is expected if the drive is used on such a network.

If the provisions under Second environment (drive of category C3) cannot be met, the requirements of the standard can be met as follows: 1. It is ensured that no excessive emission is propagated to neighbouring low-voltage networks. In some cases, the inherent suppression in transformers and cables is sufficient. If in doubt, the supply transformer with static screening between the primary and secondary windings can be used.
Medium voltage network Supply transformer Neighbouring network
Static screen
Point of measurement Low voltage Equipment (victim) Equipment Equipment Low voltage Drive
2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available from the local ABB representative. 3. The motor and control cables are selected as specified in the Hardware Manual. 4. The drive is installed according to the instructions given in the Hardware Manual. WARNING! A drive of category C4 is not intended to be used on a low-voltage public network which supplies domestic premises. Radio frequency interference is expected if the drive is used on such a network.
Machinery Directive
The drive complies with the European Union Machinery Directive (98/37/EC) requirements for an equipment intended to be incorporated into machinery.
Technical data
104
C-tick marking
C-tick marking is required in Australia and New Zealand. A C-tick mark is attached to each drive in order to verify compliance with the relevant standard (IEC 61800-3 (2004) Adjustable speed electrical power drive systems Part 3: EMC product standard including specific test methods), mandated by the Trans-Tasman Electromagnetic Compatibility Scheme.
Definitions
EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to operate without problems within an electromagnetic environment. Likewise, the equipment must not disturb or interfere with any other product or system within its locality. The Trans-Tasman Electromagnetic Compatibility Scheme (EMCS) was introduced by the Australian Communication Authority (ACA) and the Radio Spectrum Management Group (RSM) of the New Zealand Ministry of Economic Development (NZMED) in November 2001. The aim of the scheme is to protect the radiofrequency spectrum by introducing technical limits for emission from electrical/ electronic products. First environment includes establishments connected to a low-voltage network which supplies buildings used for domestic purposes. Second environment includes establishments connected to a network not supplying domestic premises. Drive of category C2: drive of rated voltage less than 1000 V and intended to be installed and commissioned only by a professional when used in the first environment. Note: A professional is a person or organisation having necessary skills in installing and/or commissioning power drive systems, including their EMC aspects. Drive of category C3: drive of rated voltage less than 1000 V and intended for use in the second environment and not intended for use in the first environment. Drive of category C4: drive of rated voltage equal to or above 1000 V, or rated current equal to or above 400 A, or intended for use in complex systems in the second environment.
Compliance with IEC 61800-3 First environment (drive of category C2)

The drive complies with the limits of IEC 61800-3 with the following provisions: 1. The drive is equipped with EMC filter +E202. 2. The drive is installed according to the instructions given in the Hardware Manual. 3. The motor and control cables used are selected as specified in the Hardware Manual. 4. Maximum cable length is 100 metres. WARNING! The drive may cause radio interference if used in a residential or domestic environment. The user is required to take measures to prevent interference, in addition to the requirements for CE compliance listed above, if necessary. Note: The drive must not be equipped with the EMC filter +E202 when installed to IT (unearthed) systems. The mains becomes connected to earth potential through the EMC filter capacitors. In IT systems this may cause danger or damage the unit.
Technical data
105

The drive complies with the standard with the following provisions: 1. The drive is equipped with EMC filter +E210. The filter is suitable for TN (earthed) and IT (unearthed) systems. 2. The motor and control cables are selected as specified in the Hardware Manual. 3. The drive is installed according to the instructions given in the Hardware Manual. 4. Maximum cable length is 100 metres. WARNING! A drive of category C3 is not intended to be used on a low-voltage public network which supplies domestic premises. Radio frequency interference is expected if the drive is used on such a network.

If the provisions under Second environment (drive of category C3) cannot be met, the requirements of the standard can be met as follows: 1. It is ensured that no excessive emission is propagated to neighbouring low-voltage networks. In some cases, the inherent suppression in transformers and cables is sufficient. If in doubt, the supply transformer with static screening between the primary and secondary windings is strongly recommended.
Medium voltage network Supply transformer Neighbouring network
Static screen
Point of measurement Low voltage Equipment (victim) Equipment Equipment Low voltage Drive
2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available from the local ABB representative. 3. The drive is installed according to the instructions given in the Hardware Manual. 4. The motor and control cables used are selected as specified in the Hardware Manual. WARNING! A drive of category C4 is not intended to be used on a low-voltage public network which supplies domestic premises. Radio frequency interference is expected if the drive is used on such a network.
Technical data
106
UL/CSA markings
The ACS800-04, ACS800-U4 and ACS800-04M are C-UL US listed and CSA marked. The approval is valid with rated voltages (up to 600 V).
UL
The drive is suitable for use on a circuit capable of delivering not more than 100 kA rms symmetrical amperes at the drive nominal voltage (600 V maximum for 690 V units) when protected by fuses given in the NEMA data fuse table. The ampere rating is based on tests done according to UL 508C. The drive provides overload protection in accordance with the National Electrical Code (US). See ACS800 Firmware Manual for setting. Default setting is off, must be activated at start-up. The drives are to be used in a heated indoor controlled environment. See section Ambient conditions for specific limits. Brake chopper - ABB has brake choppers that, when applied with appropriately sized brake resistors, will allow the drive to dissipate regenerative energy (normally associated with quickly decelerating a motor). Proper application of the brake chopper is defined in chapter Resistor braking.
Equipment warranty and liability

The manufacturer warrants the equipment supplied against defects in design, materials and workmanship for a period of twelve (12) months after installation or twenty-four (24) months from date of manufacturing, whichever first occurs. The local ABB office or distributor may grant a warranty period different to the above and refer to local terms of liability as defined in the supply contract. The manufacturer is not responsible for any costs resulting from a failure if the installation, commissioning, repair, alternation, or ambient conditions of the drive do not fulfil the requirements specified in the documentation delivered with the unit and other relevant documentation. units subjected to misuse, negligence or accident units comprised of materials provided or designs stipulated by the purchaser.
In no event shall the manufacturer, its suppliers or subcontractors be liable for special, indirect, incidental or consequential damages, losses or penalties. This is the sole and exclusive warranty given by the manufacturer with respect to the equipment and is in lieu of and excludes all other warranties, express or implied, arising by operation of law or otherwise, including, but not limited to, any implied warranties of merchantability or fitness for a particular purpose. If you have any questions concerning your ABB drive, please contact the local distributor or ABB office. The technical data, information and specifications are valid at the time of printing. The manufacturer reserves the right to modifications without prior notice.
Technical data
107
Resistor braking
This chapter describes how to select, protect and wire brake choppers and resistors. The chapter also contains the technical data.

This chapter applies to the ACS800-01/U1 (frame sizes R2 to R6), ACS800-02/U2 (frame sizes R7 and R8), ACS800-04/U4 (frame sizes R7 and R8) and ACS800-07/ U7 (frame sizes R6, R7 and R8).
Availability of brake choppers and resistors for the ACS800

Frame R2 and R3 drives and 690 V units of frame size R4 have a built-in brake chopper as standard equipment. For other units, brake choppers are optionally available as built-in units, indicated in the type code by +D150. Resistors are available as add-on kits. For the ACS800-07/U7, resistors are available as factory installed.
How to select the correct drive/chopper/resistor combination

1. Calculate the maximum power (Pmax) generated by the motor during braking. 2. Select a suitable drive / brake chopper / brake resistor combination for the application according to the following tables (take account of other factors in the drive selection also). The following condition must be met: Pbrcont > Pmax where
Pbr denotes Pbr5, Pbr10, Pbr30, Pbr60, or Pbrcont depending on the duty cycle.
3. Check the resistor selection. The energy generated by the motor during a 400second period must not exceed the resistor heat dissipation capacity ER.
If the ER value is not sufficient, it is possible to use a four-resistor assembly in which two standard resistors are connected in parallel, two in series. The ER value of the four-resistor assembly is four times the value specified for the standard resistor.
Resistor braking
108
Note: A resistor other than the standard resistor can be used provided that: its resistance is not lower than the resistance of the standard resistor. WARNING! Never use a brake resistor with a resistance below the value specified for the particular drive / brake chopper / resistor combination. The drive and the chopper are not able to handle the overcurrent caused by the low resistance. the resistance does not restrict the braking capacity needed, i.e., Pmax < where
Pmax UDC maximum power generated by the motor during braking voltage over the resistor during braking, e.g., 1.35 1.2 415 VDC (when supply voltage is 380 to 415 VAC), 1.35 1.2 500 VDC. (when supply voltage is 440 to 500 VAC) or R 1.35 1.2 690 VDC (when supply voltage is 525 to 690 VAC). resistor resistance (ohm) UDC R
2
the heat dissipation capacity (ER) is sufficient for the application (see step 3 above).
Optional brake chopper and resistor(s) for the ACS800-01/U1

The nominal ratings for dimensioning the brake resistors for the ACS800-01 and ACS800-U1 are given below at an ambient temperature of 40 C (104 F).
ACS800-01 type Braking power Brake resistor(s) ACS800-U1 type of the chopper and the drive Type Pbrcont (kW) 230 V units -0001-2 -0002-2 -0003-2 -0004-2 -0005-2 -0006-2 -0009-2 -0011-2 -0016-2 -0020-2 -0025-2 -0030-2 -0040-2 -0050-2 -0060-2 -0070-2 0.55 0.8 1.1 1.5 2.2 3.0 4.0 5.5 11 17 23 28 33 45 56 68 SACE08RE44 SACE08RE44 SACE08RE44 SACE08RE44 SACE15RE22 SACE15RE22 SACE15RE22 SACE15RE13 SAFUR90F575 SAFUR90F575 SAFUR80F500 SAFUR125F500 SAFUR125F500 2xSAFUR125F500 2xSAFUR125F500 2xSAFUR125F500
R (ohm) 44 44 44 44 22 22 22 13 8 8 6 4 4 2 2 2
ER (kJ) 210 210 210 210 420 420 420 435 1800 1800 2400 3600 3600 7200 7200 7200
PRcont (kW) 1 1 1 1 2 2 2 2 4.5 4.5 6 9 9 18 18 18
Resistor braking
109
ACS800-01 type
Braking power Brake resistor(s) ACS800-U1 type of the chopper and the drive Type Pbrcont (kW) 400 V units -0003-3 -0004-3 -0005-3 -0006-3 -0009-3 -0011-3 -0016-3 -0020-3 -0025-3 -0030-3 -0040-3 -0050-3 -0060-3 -0075-3 -0070-3 -0100-3 -0120-3 -0135-3 -0165-3 500 V units -0004-5 -0005-5 -0006-5 -0009-5 -0011-5 -0016-5 -0020-5 -0025-5 -0030-5 -0040-5 -0050-5 -0060-5 -0070-5 -0105-5 -0100-5 -0120-5 -0140-5 -0165-5 -0205-5 1.1 1.5 2.2 3.0 4.0 5.5 7.5 11 23 28 33 45 56 70 68 83 113 132 132 1.5 2.2 3.0 4.0 5.5 7.5 11 15 28 33 45 56 68 83 83 113 135 160 160 SACE08RE44 SACE08RE44 SACE08RE44 SACE08RE44 SACE08RE44 SACE15RE22 SACE15RE22 SACE15RE22 SACE15RE13 SACE15RE13 SAFUR90F575 SAFUR90F575 SAFUR90F575 SAFUR80F500 SAFUR80F500 SAFUR125F500 SAFUR125F500 SAFUR200F500 SAFUR200F500 SACE08RE44 SACE08RE44 SACE08RE44 SACE08RE44 SACE08RE44 SACE15RE22 SACE15RE22 SACE15RE22 SACE15RE13 SACE15RE13 SAFUR90F575 SAFUR90F575 SAFUR90F575 SAFUR80F500 SAFUR125F500 SAFUR125F500 SAFUR125F500 SAFUR125F500 SAFUR125F500
R (ohm) 44 44 44 44 44 22 22 22 13 13 8 8 8 3 6 4 4 2.7 2.7 44 44 44 44 44 22 22 22 13 13 8 8 8 6 4 4 4 4 4
ER (kJ) 210 210 210 210 210 420 420 420 435 435 1800 1800 1800 2400 2400 3600 3600 5400 5400 210 210 210 210 210 420 420 420 435 435 1800 1800 1800 2400 3600 3600 3600 3600 3600
PRcont (kW) 1 1 1 1 1 2 2 2 2 2 4.5 4.5 4.5 6 6 9 9 13.5 13.5 1 1 1 1 1 2 2 2 2 2 4.5 4.5 4.5 6 9 9 9 9 9
Resistor braking
110
ACS800-01 type
Braking power Brake resistor(s) ACS800-U1 type of the chopper and the drive Type Pbrcont (kW) 690 V units -0011-7 -0016-7 -0020-7 -0025-7 -0030-7 -0040-7 -0050-7 -0060-7 -0070-7 -0100-7 -0120-7 -0145-7 -0175-7 -0205-7 8 11 16 22 28 22/33 1) 45 56 68 83 113 160 160 160 SACE08RE44 SACE08RE44 SACE08RE44 SACE08RE44 SACE15RE22 SACE15RE22 SACE15RE13 SACE15RE13 SAFUR90F575 SAFUR90F575 SAFUR80F500 SAFUR80F500 SAFUR80F500 SAFUR80F500
R (ohm) 44 44 44 44 22 22 13 13 8 8 6 6 6 6
ER (kJ) 210 210 210 210 420 420 435 435 1800 1800 2400 2400 2400 2400
PRcont (kW) 1 1 1 1 2 2 2 2 4.5 4.5 6 6 6 6

PDM code 00096931-J
PbrcontThe drive and the chopper will withstand this continuous braking power. The braking is considered continuous if the braking time exceeds 30 s. Note: Check that the braking energy transmitted to the specified resistor(s) in 400 seconds does not exceed ER. R Resistance value for the listed resistor assembly. Note: This is also the minimum allowed resistance for the brake resistor. Short energy pulse that the resistor assembly withstands every 400 seconds. This energy will heat the resistor ER element from 40 C (104 F) to the maximum allowable temperature. PRcont Continuous power (heat) dissipation of the resistor when placed correctly. Energy ER dissipates in 400 seconds. 1) 22 kW with standard 22 ohm resistor and 33 kW with 3237 ohm resistor All braking resistors must be installed outside the converter module. The SACE brake resistors are built in an IP 21 metal housing. The SAFUR brake resistors are built in an IP 00 metal frame. Note: The SACE and SAFUR resistors are not UL listed
Resistor braking
111
Optional brake chopper and resistor(s) for the ACS800-02/U2, ACS800-04/ 04M/U4 and ACS800-07/U7
The nominal ratings for dimensioning the brake resistors for the ACS800-02/U2, ACS800-04/04M/U4 and ACS800-07/U7 are given below at an ambient temperature of 40 C (104 F).
ACS800 type Frame Braking power of the chopper and size the drive 10/60 s 30/60 s 5/60 s Pbr5 (kW) 230 V units -0080-2 -0100-2 -0120-2 -0140-2 -0170-2 -0210-2 -0230-2 -0260-2 -0300-2 400 V units -0070-3 -0100-3 -0120-3 -0130-3* -0140-3 -0170-3 -0210-3 -0260-3 -0320-3 -0400-3 -0440-3 -0490-3 500 V units -0100-5 -0120-5 -0140-5 -0150-5* -0170-5 -0210-5 -0260-5 -0270-5** -0300-5** -0320-5 -0400-5 -0440-5 -0490-5 -0550-5 -0610-5 R7 R7 R7 R8 R8 R8 R8 R8 R8 R6 R6 R6 R6 R7 R7 R7 R8 R8 R8 R8 R8 R6 R6 R6 R6 R7 R7 R7 R8 R8 R8 R8 R8 R8 R8 R8 68 83 105 135 135 165 165 223 223 135 165 165 240 300 375 473 500 165 198 198 1) 240 280 300 375 473 480 600 600 3) 68 83 67 135 135 165 165 170 170 135 150 150 240 300 375 355 355 132 2) 132 2) 132 2) 240 280 300 375 473 480 400 4) 400 4) 68 83 60 135 135 165 165 125 125 100 100 100 240 300 273 237 237 120 120 120 240 280 300 375 450 470 300 300 54 54 40 84 84 98 113 64 64 68 83 113 113 80 80 80 173 143 130 120 120 83 113 135 135 80 80 80 240 280 300 234 195 210 170 170 SAFUR160F380 SAFUR160F380 2xSAFUR200F500 2xSAFUR160F380 2xSAFUR160F380 2xSAFUR160F380 2xSAFUR160F380 4xSAFUR160F380 4xSAFUR160F380 SAFUR80F500 SAFUR125F500 SAFUR125F500 SAFUR125F500 SAFUR200F500 SAFUR200F500 SAFUR200F500 2XSAFUR210F575 2xSAFUR200F500 4xSAFUR125F500 4xSAFUR210F575 4xSAFUR210F575 SAFUR125F500 SAFUR125F500 SAFUR125F500 SAFUR125F500 SAFUR200F500 SAFUR200F500 SAFUR200F500 2xSAFUR125F500 2xSAFUR125F500 2xSAFUR125F500 2XSAFUR210F575 2xSAFUR200F500 2xSAFUR200F500 4xSAFUR125F500 4xSAFUR125F500 1.78 1.78 1.35 0.89 0.89 0.89 0.89 0.45 0.45 6 4 4 4 2.70 2.70 2.70 1.70 1.35 1.00 0.85 0.85 4 4 4 4 2.70 2.70 2.70 2.00 2.00 2.00 1.70 1.35 1.35 1.00 1.00 3600 3600 10800 7200 7200 7200 7200 14400 14400 2400 3600 3600 3600 5400 5400 5400 8400 10800 14400 16800 16800 3600 3600 3600 3600 5400 5400 5400 7200 7200 7200 8400 10800 10800 14400 14400 9 9 27 18 18 18 18 36 36 6 9 9 9 13.5 13.5 13.5 21 27 36 42 42 9 9 9 9 13.5 13.5 13.5 18 18 18 21 27 27 36 36 Pbr10 (kW) Pbr30 (kW) Pbrcont (kW) Brake resistor(s) Type R (ohm) ER (kJ) PRcont (kW)
Resistor braking
112
ACS800 type
Frame Braking power of the chopper and size the drive 5/60 s 10/60 s 30/60 s Pbr5 (kW) Pbr10 (kW) 110 110 110 120 300 375 430 400 400 400 Pbr30 (kW) 90 90 90 100 300 375 430 315 315 315 Pbrcont (kW) 45 55 75 75 75 75 80 260 375 385 225 225 225
Brake resistor(s) Type R (ohm) ER (kJ) PRcont (kW)
690 V units -0070-7 -0100-7 -0120-7 -0140-7 -0170-7 -0210-7 -0260-7 -0320-7 -0400-7 -0440-7 -0490-7 -0550-7 -0610-7 R6 R6 R6 R7 R7 R7 R7 R8 R8 R8 R8 R8 R8 125 5) 125 6) 125 6) 135 7) 300 375 430 550 550 550 SAFUR90F575 SAFUR80F500 SAFUR80F500 SAFUR80F500 SAFUR80F500 SAFUR80F500 SAFUR80F500 SAFUR200F500 SAFUR200F500 SAFUR200F500 2xSAFUR125F500 2xSAFUR125F500 2xSAFUR125F500 8.00 6.00 6.00 6.00 6.00 6.00 6.00 2.70 2.70 2.70 2.00 2.00 2.00 1800 2400 2400 2400 2400 2400 2400 5400 5400 5400 7200 7200 7200 4.5 6 6 6 6 6 6 13.5 13.5 13.5 18 18 18
PDM code 00096931-J
Pbr5 Pbr10 Pbr30

t
Maximum braking power of the drive with the specified resistor(s). The drive and the chopper will withstand this braking power for 5 seconds per minute. The drive and the chopper will withstand this braking power for 10 seconds per minute. The drive and the chopper will withstand this braking power for 30 seconds per minute.
Pbrcon The drive and the chopper will withstand this continuous braking power. The braking is considered continuous if the braking time exceeds 30 s. Note: Check that the braking energy transmitted to the specified resistor(s) in 400 seconds does not exceed ER.
R ER
Resistance value for the resistor assembly. Note: This is also the minimum allowed resistance for the brake resistor. Short energy pulse that the resistor assembly withstands every 400 seconds. This energy will heat the resistor element from 40 C (104 F) to the maximum allowable temperature.
PRcont Continuous power (heat) dissipation of the resistor when placed correctly. Energy ER dissipates in 400 seconds. * ** 1)
2) 3)
ACS800-0x types only ACS800-Ux types only 240 kW possible if ambient temperature is below 33 C (91 F) 160 kW possible if ambient temperature is below 33 C (91 F) 630 kW possible if ambient temperature is below 33 C (91 F) 450 kW possible if ambient temperature is below 33 C (91 F) 135 kW possible if ambient temperature is below 33 C (91 F) 148 kW possible if ambient temperature is below 33 C (91 F) 160 kW possible if ambient temperature is below 33 C (91 F)
4) 5) 6) 7)
Resistor braking
113
Combined braking cycles for R7:

Examples
Pbr Pbr5 or Pbr10 Pbr30 Pbrcont

No braking
max 5 s or 10 s
t
min. 30 s max 30 s min. 30 s max 30 s min. 30 s
After Pbr5, Pbr10 or Pbr30 braking, the drive and the chopper will withstand Pbrcont continuously. Pbr5, Pbr10 or Pbr30 braking is allowed once every minute. After Pbrcont braking, there has to be a pause of at least 30 seconds without any braking if the subsequent braking power is greater than Pbrcont. After Pbr5 or Pbr10 braking, the drive and the chopper will withstand Pbr30 within a total braking time of 30 seconds. Pbr10 braking is not acceptable after Pbr5 braking. Combined braking cycles for R8:
Examples
Pbr
max 5 s, 10 s or 30 s
Pbr5, Pbr10 or Pbr30 Pbrcont

No braking
min. 60 s min. 60 s
After Pbr5, Pbr10 or Pbr30 braking, the drive and the chopper will withstand Pbrcont continuously. (Pbrcont is the only allowed braking power after Pbr5, Pbr10 or Pbr30.) Pbr5, Pbr10 or Pbr30 braking is allowed once every minute. After Pbrcont braking, there has to be a pause of at least 60 seconds without any braking if the subsequent braking power is greater than Pbrcont.
All braking resistors must be installed outside the converter module. The resistors are built in an IP 00 metal frame. The 2xSAFUR and 4xSAFUR resistors are connected in parallel. Note: The SAFUR resistors are not UL listed.
Resistor installation and wiring

All resistors must be installed outside the drive module in a place where they will cool. WARNING! The materials near the brake resistor must be non-flammable. The surface temperature of the resistor is high. Air flowing from the resistor is of hundreds of degrees Celsius. Protect the resistor against contact.
Resistor braking
114
Use the cable type used for drive input cabling (refer to chapter Technical data) to ensure the input fuses will also protect the resistor cable. Alternatively, twoconductor shielded cable with the same cross-sectional area can be used. The maximum length of the resistor cable(s) is 10 m (33 ft). For the connections, see the power connection diagram of the drive. ACS800-07/U7 If ordered, the resistors are factory installed in a cubicle(s) next to the drive cabinet.
Protection of frame sizes R2 to R5 (ACS800-01/U1)

It is highly recommended to equip the drive with a main contactor for safety reasons. Wire the contactor so that it opens in case the resistor overheats. This is essential for safety since the drive will not otherwise be able to interrupt the main supply if the chopper remains conductive in a fault situation. Below is a simple example wiring diagram.
L1 L2 L3
1
Fuses
1 3 5
OFF
13
14
ON
4
ACS800 U1 V1 W1
K1
Thermal switch (standard in ABB resistors)
Protection of frame size R6 (ACS800-01, ACS800-07) and frame sizes R7 and R8 (ACS800-02, ACS800-04, ACS800-07)
A main contactor is not required for protecting against resistor overheating when the resistor is dimensioned according to the instructions and the internal brake chopper is in use. The drive will disable power flow through the input bridge if the chopper remains conductive in a fault situation. Note: If an external brake chopper (outside the drive module) is used, a main contactor is always required. A thermal switch (standard in ABB resistors) is required for safety reasons. The cable must be shielded and not longer than the resistor cable.
Resistor braking
115
With Standard Control Program, wire the thermal switch as shown below. By default, the drive will stop by coasting when the switch opens.
RMIO:X22 or X2: X22 1 2 3 4 5 6 7 8 9 10 11 DI1 DI2 DI3 DI4 DI5 DI6 +24VD +24VD DGND1 DGND2 DIIL
Thermal switch (standard in ABB resistors)
For other control programs, the thermal switch may be wired to a different digital input. Programming of the input to trip the drive by EXTERNAL FAULT may be needed. See the appropriate firmware manual.
Brake circuit commissioning

For Standard Control Program: Enable the brake chopper function (parameter 27.01). Switch off the overvoltage control of the drive (parameter 20.05). Check the resistance value setting (parameter 27.03). Frame sizes R6, R7 and R8: Check the setting of parameter 21.09. If stop by coasting is required, select OFF2 STOP. For the use of the brake resistor overload protection (parameters 27.02...27.05), consult an ABB representative. WARNING! If the drive is equipped with a brake chopper but the chopper is not enabled by parameter setting, the brake resistor must be disconnected because the protection against resistor overheating is then not in use. For settings of other control programs, see the appropriate firmware manual.
Resistor braking
116
Resistor braking
ABB Oy AC Drives P.O. Box 184 FI-00381 HELSINKI FINLAND Telephone +358 10 22 11 Fax +358 10 22 22681 Internet www.abb.com
ABB Inc. Automation Technologies Drives & Motors 16250 West Glendale Drive New Berlin, WI 53151 USA Telephone 262 785-3200 800-HELP-365 Fax 262 780-5135
ABB Beijing Drive Systems Co. Ltd. No. 1, Block D, A-10 Jiuxianqiao Beilu Chaoyang District Beijing, P.R. China, 100015 Telephone +86 10 5821 7788 Fax +86 10 5821 7618 Internet www.abb.com
3AFE64671006 Rev F EN EFFECTIVE: 15.6.2007

Hardware Manual ACS800-04 and ACS800-04M Drive Modules (45 To 560 KW) ACS800-U4 Drive Modules (60 To 600 HP)

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Hardware Manual ACS800-04 and ACS800-04M Drive Modules (45 To 560 KW) ACS800-U4 Drive Modules (60 To 600 HP)

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Hardware Manual ACS800-04 and ACS800-04M Drive Modules (45 To 560 KW) ACS800-U4 Drive Modules (60 To 600 HP)

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Available Formats

ACS800

ACS800 Single Drive Manuals

3AFE64671006 Rev F EN EFFECTIVE: 15.6.2007

2007 ABB Oy. All Rights Reserved.

NEW (page 6): Safety / Installation and maintenance work

CHANGED (page 11): Safety / Permanent magnet motor

CHANGED (page 23): The ACS800-04/U4

NEW (pages 26-27): Type code

NEW (page 43): Emergency stop

NEW (page 46): Safe torque off

CHANGED (page 82): LEDs

NEW (page 100): Safe torque off (+Q967): ASTO-21 board

NEW (page 100): Ambient conditions

To which products this chapter applies

Use of warnings and notes

Installation and maintenance work

Permanent magnet motor

About this manual

Common chapters for several products

Categorization according to the frame size

Categorization according to the plus code

About this manual

Other related manuals

Installation, commissioning and operating flowchart

Plan the installation.

About this manual

Check the installation site.

Route the cables.

Planning the electrical installation: Routing the cables

Check the insulation of the motor and the motor cable.

Electrical installation: Checking the insulation of the assembly

Electrical installation, Resistor braking (optional)

Commission the drive.

Appropriate firmware manual

Commission the optional brake chopper (if present).

Operating of the drive: start, stop, speed control etc.

Appropriate firmware manual

Product and service inquiries

About this manual

Providing feedback on ABB Drives manuals

About this manual

The ACS800-04/U4 and ACS800-04M

Drive Control Unit (RDCU)

Additional holes for fastening the cable terminals

Alternative output cable terminals (when no vertical busbars are used)

The ACS800-04/U4 and ACS800-04M

Output busbars on the short side of the module

Frame size R8 Drive Control Unit (RDCU)

The ACS800-04/U4 and ACS800-04M

Type designation label

The ACS800-04/U4 and ACS800-04M

The ACS800-04/U4 and ACS800-04M

The ACS800-04/U4 and ACS800-04M

Brake chopper (optional)

The ACS800-04/U4 and ACS800-04M

Connections of the Drive Control Unit (RDCU) in frame sizes R7 and R8

APOW 2100 mm (83 in.)

External control connections to RMIO board

Control panel CDP312R (optional)