ACS 800

Hardware Manual
ACS800-01 Drives (0.55 to 110 kW)
ACS800-U1 Drives (0.75 to 150 HP)
ACS 800 Single Drive Manuals

HARDWARE MANUALS (appropriate manual is included in the

delivery)

ACS800-01/U1 Hardware Manual 0.55 to 110 kW (0.75 to 150 HP)

3AFE 64382101 (English)
ACS800-02/U2 Hardware Manual 90 to 500 kW (125 to 600 HP)
3AFE 64567373 (English)
ACS800-04/U4 Hardware Manual 90 to 500 kW (125 to 600 HP)
3AFE 64671006 (English)
ACS800-07/U7 Hardware Manual 45 to 560 kW (50 to 600 HP)
3AFE 64702165 (English)
ACS800-07/U7 Dimensional Drawings 45 to 560 kW (50 to
600 HP) 3AFE 64775421
ACS800-07 Hardware Manual 500 to 2800 kW
3AFE 64731165 (English)
ACS800-17 Hardware Manual 75 to 1120 kW
3AFE 64681338 (English)

• Safety instructions
• Electrical installation planning
• Mechanical and electrical installation
• Motor control and I/O board (RMIO)
• Maintenance
• Technical data
• Dimensional drawings
• Resistor braking

FIRMWARE MANUALS, SUPPLEMENTS AND GUIDES

(appropriate documents are included in the delivery)

Standard Application Program Firmware Manual

3AFE 64527592 (English)
System Application Program Firmware Manual
3AFE 63700177 (English)
Application Program Template Firmware Manual
3AFE 64616340 (English)
Master/Follower 3AFE 64590430 (English)
PFC Application Program Firmware Manual
3AFE 64649337 (English)
Extruder Control Program Supplement 3AFE 64648543 (English)
Centrifuge Control Program Supplement
3AFE 64667246 (English)
Traverse Control Program Supplement 3AFE 64618334 (English)
Crane Control Program Firmware Manual 3BSE 11179 (English)
Adaptive Programming Application Guide
3AFE 64527274 (English)

OPTION MANUALS (delivered with optional equipment)

Fieldbus Adapters, I/O Extension Modules etc.

 ACS800-01 Drives
0.55 to 110 kW
ACS800-U1 Drives
0.75 to 150 HP

Hardware Manual

3AFE 64382101 Rev D EN

EFFECTIVE: 17.6.2003

ã 2003 ABB Oy. All Rights Reserved.

 5

Safety instructions

What this chapter contains

This chapter contains the safety instructions which you must follow when installing,
operating and servicing the drive. If ignored, physical injury or death may follow, or
damage may occur to the drive, the motor or driven equipment. Read the safety
instructions before you work on the unit.

To which products this chapter applies

This chapter applies to the ACS800-01/U1, the ACS800-02/U2 and the ACS800-04/
U4.

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.

Safety instructions
6

Installation and maintenance work

These warnings are intended for all who work on the drive, motor cable or motor.
Ignoring the instructions can cause physical injury or death.

Only qualified electricians are allowed to install and maintain the drive.

• Never work on the drive, the motor cable or the motor when main power is
applied. After switching off the input power, always wait for 5 min to let the
intermediate circuit capacitors discharge before you start working on the drive,
the motor or the motor cable.
Always ensure by measuring with a multimeter (impedance at least 1 Mohm)
that:
1. Voltage between drive input phases 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 tests without disconnecting the drive from the
cabling.

• 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.

• ACS800-04: the busbar ends on both sides of the pedestal are at a

dangerously high voltage when the input power is on, regardless of whether the
motor is running or not.

Safety instructions
 7

WARNING! The printed circuit boards contain components sensitive to electrostatic

discharge. Wear a grounding wrist band when handling the boards. Do not touch the
boards unnecessarily.

Grounding
These instructions are intended for all who are responsible for the grounding of the
drive. Incorrect grounding can cause physical injury, death or equipment malfunction
and increase electromagnetic interference.

• Ground the drive, the motor and adjoining equipment to ensure personnel
safety in all circumstances, and to reduce electromagnetic emission and pick-
up.

• Make sure that grounding conductors are adequately sized as required by

safety regulations.

• In a multiple-drive installation, connect each drive separately to protective

earth (PE).

• ACS800-01: 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.
(ACS800-02: 360° high frequency grounding of cable entries is not required at
the drive end.)

• Do not install a drive with EMC filter option +E202 or +E200 (available for
ACS800-01 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.

Fibre optic cables

WARNING! Handle the fibre optic cables with care. When unplugging optic cables,
always grab the connector, not the cable itself. Do not touch the ends of the fibres
with bare hands as the fibre is extremely sensitive to dirt. The maximum allowed
bend radius is 25 mm (1 in.).

Safety instructions
8

Mechanical installation
These notes are intended for all who install the drive. Handle the unit carefully to
avoid damage and injury.

• ACS800-01: 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.

• Make sure that dust from drilling does not enter the drive when installing.
Electrically conductive dust inside the unit may cause damage or lead to
malfunction.

• Ensure sufficient cooling.

• Do not fasten the drive by riveting or welding.

Operation
These warnings are intended for all who plan the operation of the drive or operate
the drive. Ignoring the instructions can cause physical injury or death or damage the
equipment.

• Before adjusting the drive and putting it into service, make sure that the motor
and all driven equipment are suitable for operation throughout the speed range
provided by the drive. The drive can be adjusted to operate the motor at
speeds above and below the speed provided by connecting the motor directly
to the power line.

• Do not activate automatic fault reset functions of the Standard Application

Program if dangerous situations can occur. When activated, these functions
will reset the drive and resume operation after a fault.

• Do not control the motor with the disconnecting device (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 Application Program) will start immediately after fault reset unless the
drive is configured for 3-wire (a pulse) start/stop.

• When the control location is not set to Local (L not shown in the status row of
the display), the stop key on the control panel will not stop the drive. To stop
the drive using the control panel, press the LOC/REM key and then the stop
key .

Safety instructions
 9

Permanent magnet motor

These are additional warnings concerning permanent magnet motor drives.

WARNING! Do not work on the drive when the permanent magnet motor is rotating.
Also, when the supply power is switched off and the inverter is stopped, a rotating
permanent magnet motor feeds power to the intermediate circuit of the drive and the
supply connections become live.

Installation and maintenance work

• Disconnect the motor from the drive with a safety switch
and additionally if possible
• lock the motor shaft and ground the motor connection terminals temporarily by
connecting them together as well as to the PE.

Operation
Do not run the motor over the rated speed. Motor overspeed leads to overvoltage
which may explode the capacitors in the intermediate circuit of the drive.

Safety instructions
10

Safety instructions
 11

Table of contents

ACS 800 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
Fibre optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Permanent magnet motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Table of contents

About this manual

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Common chapters for several products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Categorization according to the frame size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation and commissioning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

The ACS800-01/U1
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
The ACS800-01/U1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Main circuit and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Mechanical installation
Unpacking the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Table of contents
12

Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Requirements for the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Free space around the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Mounting the drive on the wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
UL 12 units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Cabinet installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Preventing cooling air recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Unit above another . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Planning the electrical installation

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
To which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Checking the compatibility of the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Protecting the motor winding and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Permanent magnet synchronous motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Supply connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Disconnecting device (means) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
ACS800-01, ACS800-U1, ACS800-02 and ACS800-U2 without the enclosure extension,
ACS800-04, ACS800-U4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
ACS800-U2 with the enclosure extension, ACS800-07 and ACS800-U7 . . . . . . . . . . .34
EU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
US . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Mains cable (AC line cable) short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
ACS800-01/U1, ACS800-02/U2 without enclosure extension and ACS800-04/U4 . . . .35
Drive AC fuses (ACS800-07/U7 and ACS800-02/U2 with enclosure extension) . . . . . . . . . .36
Operating time of the fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Ground fault protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Emergency stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
ACS800-07/U7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Restarting after an emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Prevention of Unexpected Start (ACS800-07/U7 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Power factor compensation capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Equipment connected to the motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Installation of safety switches, contactors, connection boxes, etc. . . . . . . . . . . . . . . . . . . . . .41
Bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Before opening a contactor (DTC control mode selected) . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Protecting the relay output contacts and attenuating disturbances in case of inductive loads . . . . .42

Table of contents
 13

Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Connection of a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Conductor stripping lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Wall installed units (European version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Power cable installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Wall installed units (US version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Warning sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Cabinet installation (IP 21, UL type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Frame size R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Frame size R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
360 degrees grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
When the outer surface of the shield is covered with non-conductive material . . . . . . 58
Connecting the shield wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Cabling of I/O and fieldbus modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Pulse encoder module cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Fastening the control cables and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Installation of optional modules and PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Fibre optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
External +24 V power supply for the RMIO board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Motor control and I/O board (RMIO)

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
To which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Note for the ACS800-02 with enclosure extension and the ACS800-07 . . . . . . . . . . . . . . . . . . . . . 61
Note for external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
External control connections (non-US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
External control connections (US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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RMIO board specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

Analogue inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Constant voltage output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Auxiliary power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Analogue outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
DDCS fibre optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
24 VDC power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Installation checklist
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Maintenance
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Fan replacement (R2, R3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Fan replacement (R4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Fan replacement (R5, R6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Additional fan in IP 55 units and certain IP 21 units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Replacement (R2, R3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Replacement (R4, R5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Replacement (R6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

Technical data
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
IEC ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Mains cable fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Cable entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Dimensions, weights and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Input power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

Table of contents
 15

Degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Compliance with the EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
First environment (restricted distribution) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Second environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
“C-tick” marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Compliance with IEC 61800-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
First environment (restricted distribution) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Second environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Equipment warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
US tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
NEMA ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Input cable fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Cable Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
UL/CSA markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
UL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Dimensional drawings
Frame size R2 (IP 21, UL type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Frame size R2 (IP 55) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Frame size R3 (IP 21, UL type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Frame size R3 (IP 55) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Frame size R4 (IP 21, UL type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Frame size R4 (IP 55) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Frame size R5 (IP 21, UL type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Frame size R5 (IP 55) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Frame size R6 (IP 21, UL type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Frame size R6 (IP 55) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Frame size R2 (UL type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Frame size R3 (UL type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Frame size R4 (UL type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Frame size R5 (UL type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Frame size R6 (UL type 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Resistor braking
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
To which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Availability of brake choppers and resistors for the ACS 800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
How to select the correct drive/chopper/resistor combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Table of contents
16

Optional brake chopper and resistor(s) for the ACS800-01/U1 . . . . . . . . . . . . . . . . . . . . . . . . . . .112

Optional brake chopper and resistor(s) for the ACS800-02/U2, the ACS800-04/U4
and the ACS800-07/U7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Resistor installation and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
ACS800-07/U7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Protection of frame sizes R2 to R5 (ACS800-01/U1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Protection of frame size R6 (ACS800-01, ACS800-07) and frame sizes R7
and R8 (ACS800-02, ACS800-04, ACS800-07) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Brake circuit commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117

External +24 V power supply for the RMIO board

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
When to use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Connecting +24 V external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120

Table of contents
 17

About this manual

What this chapter contains

This chapter describes the intended audience and contents of this 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.

Intended audience
This manual is intended for people who plan the 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.
This 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 Safety instructions, Planning the electrical installation, Motor control and
I/O board (RMIO) and Resistor braking apply to several ACS 800 products which are
listed at the beginning of the chapters.

Categorization according to the frame size

Some 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 the rating tables in chapter Technical data.
The ACS800-01 is manufactured in frame sizes R2 to R6.

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 lists the steps in checking the delivery and installing and
commissioning the drive and refers to chapters/sections in this manual and other
manuals for particular tasks.

About this manual

18

The ACS800-01/U1 describes the drive.

Mechanical installation instructs how to place and mount the drive.
Planning the electrical installation instructs on the motor and cable selection, the
protections and the cable routing.
Electrical installation shows how to wire the drive.
Motor control and I/O board (RMIO) shows the external control connections to the
I/O board.
Installation checklist contains a list for checking the mechanical and electrical
installation of the drive.
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.
Dimensional drawings contains the dimensional drawings of the drive.
Resistor braking describes how to select, protect and wire brake choppers and
resistors. The chapter also contains the technical data.
External +24 V power supply for the RMIO board describes how to connect external
+24 V power supply for the RMIO board.

Installation and commissioning flowchart

Task See

Plan the installation. Technical data

Check the ambient conditions, ratings, required Planning the electrical installation
cooling air flow, input power connection, compatibility
For compliance with the European Union EMC
of the motor, motor connection, and other technical
Directive, see Technical data: CE marking
data.
Select the cables. Option manual (if optional equipment is
included)

Unpack and check the units. Mechanical installation: Unpacking the unit.
Check that all necessary optional modules and If the converter has been non-operational for
equipment are present and correct. more than one year, the converter DC link
Only intact units may be started up. capacitors need to be reformed. Ask ABB for
instructions.

If the drive is about to be connected to an IT The ACS800-01/U1: Type code. For

(ungrounded) system, check that the drive is not instructions on how to disconnect the EMC
equipped with EMC filtering. filtering, contact ABB.

About this manual

 19

Task See

Check the installation site. Mechanical installation: Before installation

Technical data

Install the drive on a wall or in a cabinet. Mechanical installation

Route the cables. Planning the electrical installation: Routing the

cables
For compliance with the European Union EMC
Directive, see Technical data: CE marking

Check the insulation of the motor and the motor Electrical installation: Checking the insulation of
cable. the assembly

Connect the power cables. Electrical installation

Connect the control and the auxiliary control cables. Electrical installation, Motor control and I/O
board (RMIO), and the optional module manual
delivered with the module.

Check the installation. Installation checklist

Commission the drive. Appropriate firmware manual

Commission the optional brake chopper (if present). Resistor braking

Inquiries
Address any inquiries about the product to the local ABB representative, quoting the
type code and the serial number of the unit. If the local ABB representative cannot
be contacted, address inquiries to the manufacturing facility (addresses and phone
numbers are on the back cover of this manual).

About this manual

20

About this manual

 21

The ACS800-01/U1

What this chapter contains

This chapter describes the operating principle and construction of the drive in short.

The ACS800-01/U1
The ACS800-01/U1 is a wall mountable drive for controlling AC motors.

Control panel CDP312R

Heat sink

Front cover

Connection box

IP 21 (UL type 1)

Control panel CDP312R Heat sink

under a hinged plastic
cover

Front cover (no connection box)

IP 55 (UL type 12)

The ACS800-01/U1
22

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. ACS800-01-
0006-5). The optional selections are given thereafter, separated by + signs (e.g.
+E202). The main selections are described below. Not all selections are available for
all types. For more information, refer to ACS 800 Ordering Information (EN code:
64556568, available on request).

Selection Alternatives
Product series ACS800 product series
Type 01 wall mounted. When no options are selected: IP 21, Control Panel
CDP312R, no EMC filter, Standard Application Program, cable
connection box (cabling from below), brake chopper in frame sizes R2
and R3, boards without coating, one set of manuals
U1 wall mounted (USA). When no options are selected: UL type 1, Control
Panel CDP312R, no EMC filter, US version of the Standard Application
Program (three-wire start/stop as default setting), US gland/conduit box,
brake chopper in frame sizes R2 and R3, boards without coating, one set
of English manuals.
Size Refer to Technical data: IEC ratings.
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
Degree of protection B056 IP 55 / UL type 12
Resistor braking D150 brake chopper
Filter E200 EMC/RFI filter for second environment TN (grounded) system,
unrestricted distribution
E202 EMC/RFI filter for first environment TN (grounded) system, restricted
distribution (the A limits)
Cabling H358 US/UK gland/conduit box
Control panel 0J400 no control panel
Fieldbus K... Refer to ACS 800 Ordering Information (EN code: 64556568).
I/O L...
Application program N...
Manual language R...
Specialities P901 = coated boards

The ACS800-01/U1
 23

Main circuit and control

Diagram
This diagram shows the control interfaces and the main circuit of the drive.

Motor
control and Optional module 1: RMBA, RAIO,
I/O board RDIO, RDNA, RLON, RIBA, RPBA,
(RMIO) RCAN, RCNA, RMBP, RETA or RTAC

External control via Optional module 2: RTAC, RAIO or

analogue/digital RDIO
inputs and outputs DDCS communication option module
3: RDCO-01, RDCO-02 or RDCO-03

Input power
= ~ Output power
~ =

Brake chopper in frame sizes R2 and R3

(optional in other frame sizes)

R- UDC+ UDC-
R+

Operation
This table describes the operation of the main circuit in short.

Component Description

six-pulse rectifier converts the three-phase AC voltage to DC voltage

capacitor bank energy storage which stabilizes the intermediate circuit DC voltage

six-pulse IGBT inverter converts the DC voltage to AC voltage and vice versa. The motor
operation is controlled by switching the IGBTs.

The ACS800-01/U1
24

Printed circuit boards

The drive contains the following printed circuit boards as standard:
• main circuit board (RINT)
• motor control and I/O board (RMIO)
• EMC filter board (RRFC) when EMC equipment is selected or varistor board
(RVAR) otherwise
• control panel (CDP 312R).

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.

The ACS800-01/U1
 25

Mechanical installation

Unpacking the unit

The drive is delivered in a box that also contains:
• plastic bag containing: screws (M3), clamps and cable lugs (2 mm2, M3) for
grounding the control cable screens
• connection box (screws and clamps included)
• residual voltage warning stickers
• hardware manual
• appropriate firmware manuals and guides
• optional module manuals
• delivery documents.
Unpack the unit as follows.

Tear

Do not lift by the cover.

Mechanical installation
26

Delivery check
Check that there are no signs of damage. Before attempting installation and
operation, check the information on the type designation label of the drive to verify
that the unit is of the correct type. The label includes an IEC and NEMA rating, UL,
C-UL, CSA and CE 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 unit’s 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 attached to the heat sink and the serial number label to
the upper part of the back plate of the unit. Example labels are shown below.

Type designation label

Serial number label

Before installation
The drive must be installed in an upright position with the cooling section facing a
wall. Check the installation site according to the requirements below. Refer to
Dimensional drawings for frame details.

Requirements for the installation site

See Technical data for the allowed operation conditions of the drive.
Wall
The wall should be as close to vertical as possible, of non-flammable material and
strong enough to carry the weight of the unit. Check that there is nothing on the wall
to inhibit the installation.
Floor
The floor/material below the installation should be non-flammable.

Mechanical installation
 27

Free space around the unit

Required free space around the drive to enable cooling air flow, service and
maintenance is shown below in millimetres and [inches]. When mounting IP 55 units
above one another, leave 200 mm (7.9 in.) free space above and below the unit.

50 [2.0]
200 [7.9]

50 [2.0] 50 [2.0] 50 [2.0] 50 [2.0]

300 [12]
50 [2.0]

IP 21 (UL 1) IP 55 (UL 12)

Air flow (side view)

Mechanical installation
28

Mounting the drive on the wall

1. Using the mounting template cut from the package, mark the locations for the four
holes. The mounting points are shown in Dimensional drawings.
2. Fix the screws or bolts to the marked locations.
3. IP 55 (UL 12) units: Remove the front cover by undoing the fixing screws.
4. Position the drive onto the screws on the wall. Note: Lift the drive by its chassis
(R6: by its lifting holes), not by its cover.
5. Tighten the screws in the wall securely.

IP 55 (UL 12)

UL 12 units
Install the hood delivered with the drive 50 mm (2.0 in.) above the top of unit.

Mechanical installation
 29

Cabinet installation
The required distance between parallel units is five millimetres (0.2 in.) in
installations without the front cover. The cooling air entering the unit must not exceed
+40 °C (+104 °F).

Preventing cooling air recirculation

Prevent air recirculation inside and outside the cabinet.
Example

HOT
Main air flow out AREA

Air baffle plates

COOL AREA

Main air flow in

Mechanical installation
30

Unit above another

Lead the out-coming cooling air away from the unit above.
Example

max.+40 °C (+104 °F)

Mechanical installation
 31

Planning the electrical installation

What this chapter contains

This chapter contains the instructions that you must follow when selecting the motor,
the cables, the protections, the cable routing and the way of operation for the drive
system. Always follow local regulations.
Note: If the recommendations given by ABB are not followed, the drive may
experience problems that the warranty does not cover.

To which products this chapter applies

This chapter applies to the ACS800-01/U1, the ACS800-02/U2, the ACS800-04/U4
and ACS800-07/U7 types up to -0610-x.

Checking the compatibility of the motor

See Technical data for the drive ratings and the motor connection data.

WARNING! Operation is not allowed if the motor nominal voltage is less than 1/2 of
the drive nominal input voltage. The allowed range of the 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.

Protecting the motor winding and bearings

The output of the drive comprises – regardless of output frequency – pulses of
approximately 1.35 times the 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 motor cable properties. This in turn can cause additional stress on the motor
insulation.
Modern variable speed drives with their fast rising voltage pulses and high switching
frequencies can cause current pulses through the motor bearings which can
gradually erode the bearing races.
The stress on motor insulation can be avoided by using optional ABB du/dt filters.
du/dt filters also reduce bearing currents.

Planning the electrical installation

32

To avoid damage to motor bearings, insulated N-end (non-driven end) bearings and
output filters from ABB must be used according to the following table. In addition, the
cables must be selected and installed according to the instructions given in this
manual. Three 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)
• light common mode filter (mainly reduces bearing currents).
The common mode filter is composed of toroidal cores installed onto the output
busbars inside the drive at the factory.

Requirements table
The following table shows how to select the motor insulation system and when 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.

Motor type Nominal mains Requirement for

voltage (AC line Motor insulation ABB du/dt filter, insulated N-end bearing and ABB common mode
voltage)
Manufacturer

system filter
PN < 100 kW 100 kW < PN < 350 kW PN > 350 kW
and or or
frame size < IEC 315 frame size > IEC 315 frame size > IEC 400
PN < 134 HP 134 HP < PN < 469 HP PN > 469 HP
and frame size < or frame size >
NEMA 500 NEMA 500
A Random- UN < 500 V Standard - +N + N + CMF
B wound M2_ 500 V < UN < 600 V Standard + du/dt + du/dt + N + du/dt + N + LCMF
and M3_
B or
Reinforced - +N + N + CMF
600 V < UN < 690 V Reinforced + du/dt + du/dt + N + du/dt + N + LCMF
Form-wound 380 V < UN < 690 V Standard n.a. + N + CMF + N + CMF
HXR and AM_
Old* form- 380 V < UN < 690 V Check with the + du/dt with voltages over 500 V + N + CMF
wound HX_ motor
and modular manufacturer.
Random- 380 V < UN < 690 V Check with the + du/dt with voltages over 500 V + N + CMF
wound HXR motor
and AM_ manufacturer.

Planning the electrical installation

 33

Motor type Nominal mains Requirement for

voltage (AC line
Motor insulation ABB du/dt filter, insulated N-end bearing and ABB common mode
voltage)
Manufacturer

system filter
PN < 100 kW 100 kW < PN < 350 kW PN > 350 kW
and or or
frame size < IEC 315 frame size > IEC 315 frame size > IEC 400
PN < 134 HP 134 HP < PN < 469 HP PN > 469 HP
and frame size < or frame size >
NEMA 500 NEMA 500
N Random- UN < 420 V Standard: ÛLL = - + N or CMF + N + CMF
O wound and 1300 V
form-wound
N 420 V < UN < 500 V Standard: ÛLL = + du/dt + du/dt + N + du/dt + N + CMF
- 1300 V
or
A
+ du/dt + CMF
B
or
B
Reinforced: ÛLL = - + N or CMF + N + CMF
1600 V, 0.2
microsecond rise
time
500 V < UN < 600 V Reinforced: ÛLL = + du/dt + du/dt + N + du/dt + N + LCMF
1600 V or
+ du/dt + CMF
or
Reinforced: ÛLL = - + N or CMF + N + CMF
1800 V
600 V < UN < 690 V Reinforced: ÛLL = + du/dt + du/dt + N + du/dt + N + LCMF
1800 V
Form-wound 600 V < UN < 690 V Reinforced: ÛLL = n.a. N + CMF N + CMF
2000 V, 0.3
microsecond rise
time

* manufactured before 1992

Note 1: The abbreviations used in the table are defined below.

Abbreviation Definition
UN nominal voltage of the supply network
ÛLL peak line-to-line voltage at motor terminals which the motor insulation must withstand
PN motor nominal power
du/dt du/dt filter at the output of the drive
CMF common mode filter +E208 (3 toroidal cores)
LCMF light common mode filter +E209 (1 toroidal core)
N N-end bearing: insulated motor non-driven end bearing
n.a. Motors of this power range are not available as standard units. Consult the motor manufacturer.

Planning the electrical installation

34

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 range “100 kW < PN < 350 kW” apply to motors with
40 kW < PN < 100 kW. The requirements of range “PN > 350 kW” apply to motors with PN within the
range of “100 kW < PN < 350 kW”.
Note 4: HXR and AMA motors
All AMA machines (manufactured in Helsinki) to be supplied by a drive have form-wound windings. All
HXR machines manufactured in Helsinki since 1997 have form-wound windings.
Note 5: ABB motors of types other than M2_, M3_, HX_ and AM_
Select according to 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.

Permanent magnet synchronous motor

Only one permanent magnet motor can be connected to the inverter output.
Install a safety switch between a permanent magnet synchronous motor and the
motor cable. The switch is needed to isolate the motor during any maintenance work
in the drive.

Supply connection

Disconnecting device (means)

ACS800-01, ACS800-U1, ACS800-02 and ACS800-U2 without the enclosure extension,
ACS800-04, ACS800-U4
Install a hand-operated input disconnecting device (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-U2 with the enclosure extension, ACS800-07 and ACS800-U7
These units are equipped with a hand-operated input disconnecting device (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 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.

Planning the electrical installation

 35

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:
• a switch-disconnector of utilization category AC-23B (EN 60947-3)
• a 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)
• a 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.

Thermal overload and short-circuit protection

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.

The drive protects the motor cable and the motor in a short-circuit situation when the
motor cable is dimensioned according to the nominal current of the drive.

Mains cable (AC line cable) short-circuit protection

Always protect the input cable with fuses. Size the fuses according to local safety
regulations, appropriate input voltage and the rated current of the drive (see
Technical Data).
ACS800-01/U1, ACS800-02/U2 without enclosure extension and ACS800-04/U4
When placed at the distribution board, standard gG (US: CC or T for the ACS800-
U1; T or L for the ACS800-U2 and the ACS800-U4) 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.

Planning the electrical installation

36

Drive AC fuses (ACS800-07/U7 and ACS800-02/U2 with enclosure extension)

ACS800-07/U7 units and ACS800-02/U2 units with enclosure extension are
equipped with standard gG or optional aR fuses listed in Technical Data. The fuses
restrict drive damage and prevent damage to adjoining equipment in case of a short-
circuit inside the drive.

Operating time of the fuses

Check that the operating time of the fuse is below 0.5 seconds. The operating
time depends on the fuse type (gG or aR), supply network impedance and the cross-
sectional area, material and length of the supply cable. In case the 0.5 seconds
operating time is exceeded with gG fuses, ultrarapid (aR) fuses will in most cases
reduce the operating time to an acceptable level. The US fuses must be of the “non-
time delay” type.
For fuse ratings, see Technical Data.

WARNING! Circuit breakers are not capable of providing sufficient protection

because they are inherently slower than fuses. Always use fuses with circuit
breakers.

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 the 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 ACS 800 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.
Pressing the stop key ( ) on the control panel of the drive, or turning the operating
switch of the drive in cabinet installed units from position “ON” to “OFF” does not
generate an emergency stop of the motor or separate the drive from dangerous
potential.

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) and controlled emergency stop
(Category 1).

Planning the electrical installation

 37

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 in cabinet installed units from
position “ON” to “START”.

Prevention of Unexpected Start (ACS800-07/U7 only)

The drive 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 drive and
machinery must be stopped using the appropriate stopping mode before using this
function. The function must not be used for stopping the drive when the drive is
running.
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.
For connections to the drive, see the circuit diagram delivered with the drive.

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.

Planning the electrical installation

38

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 an ground fault
occurs).
• 600 VAC cable is accepted for up to 500 VAC. For 690 VAC rated equipment, the
rated voltage between the conductors of the cable should be minimum 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 recommended.
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 Minimum cross-sectional area of the
conductors corresponding protective conductor
S (mm2) Sp (mm2)
S < 16 S
16 < S < 36 16
35 < S 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 motor
bearing currents and wear.

Planning the electrical installation

 39

The motor cable and its PE pigtail (twisted shield) should be kept as short as
possible in order to reduce electromagnetic emission as well as capacitive current.

Alternative power cable types

Power cable types that can be used with the drive are represented below.

Recommended
Symmetrical shielded cable: three phase conductors A separate PE conductor is required if the conductivity
and a concentric or otherwise symmetrically of the cable shield is < 50 % of the conductivity of the
constructed PE conductor, and a shield phase conductor.
PE conductor Shield
and shield Shield

PE
PE

PE Shield
A four-conductor system:
three phase conductors
and a protective
conductor.
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. The better and
tighter the shield, the lower the emission level and the bearing currents.

Copper wire screen Helix of copper tape Inner insulation

Insulation jacket

Cable core

Planning the electrical installation

40

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 VAC cable is accepted for up to 500 VAC.
1000 VAC cable is required above 500 VAC (below 600 VAC). For drives rated over
100 amperes, the power cables must be rated for 75 °C (167 °F).
Conduit
Where conduits must be coupled together, bridge the joint with a ground conductor
bonded to the conduit on each side of the joint. Bond the conduits also to the drive
enclosure. Use separate conduits for input power, motor, brake resistors, and control
wiring. Do not run motor wiring from more than one drive in the same conduit.
Armored cable / shielded power cable
The motor cables can be run in the same cable tray as other 460 V or 600 V power
wiring. Control and signal cables must not be run in the same tray as power cables.
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 (ÖLFLEX) and
Pirelli.

Power factor compensation capacitors

Do not connect power factor compensation capacitors or surge absorbers to the
motor cables (between the drive and the motor). They are not designed to be used
with drives, and will degrade motor control accuracy. They can cause permanent
damage to the drive or themselves due to the rapid changes in the drive output
voltage.
If there are power factor compensation capacitors in parallel with the three phase
input of the drive, ensure that the capacitors and the drive are not charged
simultaneously to avoid voltage surges which might damage the unit.

Planning the electrical installation

 41

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 (i.e. between the drive and the
motor):
• EU: Install the equipment in a metal enclosure with 360 degrees grounding for the
screens of both the incoming and outgoing cable, or connect the screens 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 ACS 800 application 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.

Planning the electrical installation

42

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 RO1
2 RO1
230 VAC
3 RO1
RC filter X26
1 RO2
2 RO2
230 VAC
3 RO2
Diode X27
1 RO3
2 RO3
24 VDC
3 RO3

Planning the electrical installation

 43

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 multipair cable (Figure b) is also usable.

a b
A double shielded twisted A single shielded twisted
pair cable multipair 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 VAC signals in the same cable.

Relay cable
The cable type with braided metallic screen (e.g. ÖLFLEX 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.

Planning the electrical installation

44

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 non-
conductive 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
ACS 800 Firmware Manual.

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.

Planning the electrical installation

 45

A diagram of the cable routing is below.

Motor cable
Drive
min 300 mm (12 in.)
Power cable

Input power cable Motor cable

min 200 mm (8 in.) 90 °

min 500 mm (20 in.)

Control cables

Control cable ducts

24 V 230 V 24 V 230 V

Not allowed unless the 24 V Lead 24 V and 230 V control

cable is insulated for 230 V or cables in separate ducts inside
insulated with an insulation the cabinet.
sleeving for 230 V.

Planning the electrical installation

46

Planning the electrical installation

 47

Electrical installation

What this chapter contains

This chapter describes the electrical installation procedure of the drive.

WARNING! The work described in this chapter may only be carried out by a qualified
electrician. Follow the Safety instructions on the first pages of this manual. Ignoring
the safety instructions can cause injury or death.
Make sure that the drive is disconnected from the mains (input power) during
installation. If the drive is already connected to the mains, wait for 5 min after
disconnecting mains power.

Electrical installation
48

Checking the insulation of the assembly

Every drive 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. Check the insulation of the assembly as follows.

WARNING! Check the insulation before connecting the drive to the mains. Make
sure that the drive is disconnected from the mains (input power).

1. Check that the motor cable is disconnected from the drive output terminals U2,
V2 and W2.
M 2. Measure the insulation resistances of the motor cable and the motor between
ohm each phase and the Protective Earth by using a measuring voltage of 1 kV DC.
PE
The insulation resistance must be higher than 1 Mohm.

IT (ungrounded) systems
Disconnect the EMC filter capacitors of selections +E202 and +E200 before
connecting the drive to an ungrounded system. For detailed instructions on how to
do this, please contact your local ABB distributor.

WARNING! If a drive with EMC filter selection +E202 or +E200 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.

Electrical installation
 49

Connecting the power cables

Diagram

Drive
INPUT UDC+ UDC- OUTPUT
PE U1 V1 W1 R- R+ U2 V2 W2
1) 2)

3) 4) 4)

(PE) PE (PE)
5)
V1 W1
U1
Optional brake
For alternatives, see
Planning the electrical
resistor 3 ~
installation: Motor
Disconnecting device
(means) L1 L2 L3

1), 2) Grounding of the motor cable shield at the motor end

If shielded cable is used (not required but For minimum radio frequency interference:
recommended), use a separate PE cable (1) or a • ground the cable shield 360 degrees at the lead-through of
cable with a grounding conductor (2) if the the motor terminal box
conductivity of the input cable shield is < 50 % of the
conductivity of the phase conductor.
Ground the other end of the input cable shield or PE
conductor at the distribution board. 360 degrees grounding
3) 360 degrees grounding recommended if shielded
cable
Conductive gaskets
4) 360 degrees grounding required
• or ground the cable by twisting the shield as follows:
flattened width > 1/5 · length.

b > 1/5 · a
5) Use a separate grounding cable if the conductivity of
the cable shield is < 50 % of the conductivity of the b
a
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.

Electrical installation
50

Conductor stripping lengths

Strip the conductor ends as follows to fit them inside the power cable connection
terminals.
Frame size Stripping length
mm in.
R2, R3 10 0.39
R4, R5 16 0.63
R6 28 1.10

Wall installed units (European version)

Power cable installation procedure
1. Remove the front cover (in frame size R6 the lower front cover) by releasing the
retaining clip with a screw driver and lifting the cover from the bottom outwards.
For IP 55 units, see Mechanical installation / Mounting the drive on the wall.
2. Slide the back plate of the connection box to the holes below the drive.
3. Fasten the back plate to the drive frame with two screws / three screws in frame
size R6.
4. Cut adequate holes into the rubber grommets and slide the grommets onto the
cables. Slide the cables through the holes of the bottom plate.
5. Strip off the plastic sheath of the cable under the 360 degrees grounding clamp.
Fasten the clamp onto the stripped part of the cable.
6. Connect the twisted shield of the cable to the grounding terminal. Note: cable
lugs are needed in frame sizes R2 and R3.
7. Connect the phase conductors of the mains cable to the U1, V1 and W1 terminals
and the phase conductors of the motor cable to the U2, V2 and W2 terminals.
8. Fasten the bottom plate of the connection box with two screws to the already
fastened back plate and slide the grommets into their place.
9. Secure the cables outside the unit mechanically. Connect the control cables as
described in section Connecting the control cables. Fasten the covers (see
Fastening the control cables and covers).

Electrical installation
 51

Connection box (IP 21)

Back plate Fastening hooks
2 3 2
3
Fastening screws
8
3

8
1

360 degrees grounding 4

clamp Grommet

Input cable entry Motor cable entry

Brake resistor cable entry
Control cable entry

Bottom plate

Fasten the
control
cables
between
these plates
with cable
Cover
ties

Frame sizes R2 to R4 Frame size R5

U1 V1 W1 UDC+
U2 V2 W2
R- R+ UDC-
PE

6
6 6

5 5

Input power cable Motor cable

Electrical installation
52

Frame size R6: Cable lug installation [16 to 70 mm2 (6 to 4/0 AWG) cables]

a
Isolate the ends of Connection plate
a the cable lugs with fastening screws
PE 6
insulating tape or
shrink tubing.

3 3

5 5

Frame size R6: Cable terminal installation (95 to 185 mm2 cables)

PE 6

a
a. Connect the cable to the terminal.

3 b. Connect the terminal to the drive.

3

5 5

Electrical installation
 53

Wall installed units (US version)

1. Remove the front cover (in frame size R6 the lower front cover) by releasing the
retaining clip with a screw driver and lifting the cover from the bottom outwards.
2. Make the cable entry holes in the gland box by breaking off the suitable knock-out
plates with a screw driver.
3. Fasten the cable glands to the opened holes of the gland box.
4. Fasten the gland box to the frame with two screws / three screws in frame size
R6.

Frame sizes R2 to R4

UDC+
U1 V1 W1 R- R+ UDC- U2 V2 W2

4 4
PE

3 3

Input power cable Motor cable

5. Lead the cables through the glands to the inside of the gland box.
6. Connect the PE conductors of the input and motor cables to the grounding
terminal. Note: cable lugs are needed in frame sizes R2 and R3. Connect the
separate PE conductor (if used) to the grounding terminal.
7. Connect the phase conductors of the input cable to the U1, V1 and W1 terminals
and the phase conductors of the motor cable to the U2, V2 and W2 terminals.

For frame size R6, see Wall installed units (European version) / figure Frame size
R6: Cable lug installation [16 to 70 mm2 (6 to 4/0 AWG) cables]. To meet UL
requirements, use UL listed cable lugs and tools given below or corresponding.

Electrical installation
54

Wire size Compression lug Crimping tool

kcmil/AWG Manufacturer Type Manufacturer Type No. of crimps
6 Burndy YAV6C-L2 Burndy MY29-3 1
Ilsco CCL-6-38 Ilsco ILC-10 2
4 Burndy YA4C-L4BOX Burndy MY29-3 1
Ilsco CCL-4-38 Ilsco MT-25 1
2 Burndy YA2C-L4BOX Burndy MY29-3 2
Ilsco CRC-2 Ilsco IDT-12 1
Ilsco CCL-2-38 Ilsco MT-25 1
1 Burndy YA1C-L4BOX Burndy MY29-3 2
Ilsco CRA-1-38 Ilsco IDT-12 1
Ilsco CCL-1-38 Ilsco MT-25 1
Thomas & Betts 54148 Thomas & Betts TBM-8 3
1/0 Burndy YA25-L4BOX Burndy MY29-3 2
Ilsco CRB-0 Ilsco IDT-12 1
Ilsco CCL-1/0-38 Ilsco MT-25 1
Thomas & Betts 54109 Thomas & Betts TBM-8 3
2/0 Burndy YAL26T38 Burndy MY29-3 2
Ilsco CRA-2/0 Ilsco IDT-12 1
Ilsco CCL-2/0-38 Ilsco MT-25 1
Thomas & Betts 54110 Thomas & Betts TBM-8 3
3/0 Burndy YAL27T38 Burndy MY29-3 2
Ilsco CRA-3/0 Ilsco IDT-12 1
Ilsco CCL-3/0-38 Ilsco MT-25 1
Thomas & Betts 54111 Thomas & Betts TBM-8 3
4/0 Burndy YA28-R4 Burndy MY29-3 2
Ilsco CRA-4/0 Ilsco IDT-12 1
Ilsco CCL-4/0-38 Ilsco MT-25 2
Thomas & Betts 54112 Thomas & Betts TBM-8 4

8. Tighten the clamping nuts of the cable glands.

After connecting the control cables, fasten the front covers.

Warning sticker
There are warning stickers in different languages inside the packing box of the drive.
Attach a warning sticker in the language of your choice onto the plastic skeleton
above the power cable terminals.

Cabinet installation (IP 21, UL type 1)

The drive can be installed in a cabinet without the connection box and front cover.
It is recommended:
• to ground the cable shield 360 degrees at the cabinet entry
• to lead the cable unstripped as close to the terminals as possible.
Secure the cables mechanically.

Electrical installation
 55

Protect the RMIO board terminals X25 to X27 against contact when input voltage
exceeds 50 VAC.
Frame size R5
Cover the power cable terminals as follows:
1. Cut holes for the installed cables into the clear plastic shroud.
2. Press the shroud onto the terminals.

1 2

Removal of the shroud with a screw driver:

Frame size R6
Cover the power cable terminals as follows:
1. Cut holes for the installed cables into the clear plastic shroud in cable lug
installations.
2. Press the shroud onto the terminals.

View of cable terminal

2 installation

Removal of the shroud by lifting up with a screw driver from the corner:

Electrical installation
56

Connecting the control cables

Lead the cable through the control cable entry (1).
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.

Terminals

Frame sizes R2 to R4
The control cable connection terminals are
exposed when the control panel mounting platform
is turned aside by pulling this knob. Be careful, do Detachable connection terminals (pull up)
not use excess force when pulling.
X39 for control panel cable

Optional module 1

Optional module 2

I/O cables: Ground the DDCS communication

control cable shields in the option module 3:
holes with screws. See RDCO
section 360 degrees
grounding. Place the warning
sticker here
4
3
2
1

Electrical installation
 57

Frame sizes R5 and R6

View of frame size R6

Control panel

Optional module 2

Optional module 1 DDCS communication option module 3: RDCO

Place the warning sticker here

Control cable
grounding: see Detachable connection terminals (pull up)
section 360
degrees
grounding

Electrical installation
58

360 degrees grounding

Insulation

4
3
2
1

Double shielded cable Single shielded cable

When the outer surface of the shield is covered with non-conductive material
• Strip the cable carefully (do not cut the grounding wire and the shield)
• Turn the shield inside out to expose the conductive surface.
• Wrap the grounding wire around the conductive surface.
• Slide a conductive clamp onto the conductive part.
• Fasten the clamp to the grounding plate with a screw as close as possible to the
terminals where the wires are about to be connected.

Connecting the shield wires

Single shielded cables: Twist the grounding wires of the outer shield and connect
them through the shortest possible route to the nearest grounding hole with a cable
lug and a screw. Double shielded cables: Connect each pair cable shield (twisted
grounding wires) with other pair cable shields of the same cable to the nearest
grounding hole with a cable lug and a screw.
Do not connect shields of different cables to the same cable lug and grounding
screw.
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.

Electrical installation
 59

Cabling of I/O and fieldbus modules

Module
As short as possible

Shield

4
3
2
1

Note: The RDIO module does not

include a terminal for cable shield
grounding. Ground the pair cable
shields here.

Pulse encoder module cabling

As short as
possible
Note1: If the encoder is of
1
2 unisolated type, ground the encoder
cable at the drive end only. If the
3
4

encoder is galvanically isolated

from the motor shaft and the stator
frame, ground the encoder cable
Shield

shield at the drive and the encoder

RTAC end.
Note 2: Twist the pair cable wires.

Wrap copper tape around the

stripped part of the cable under the
clamp. Be careful. Do not cut the
grounding wire. Clamp as close to
the terminals as possible.

Electrical installation
60

Fastening the control cables and covers

When all control cables are connected, fasten them together with cable ties. Units
with a connection box: fasten the cables to the entry plate with cable ties. Units with
a gland box: tighten the clamping nuts of the cable glands.

Fasten the connection box cover.

US cover

Replace the front cover.

Installation of optional modules and PC

The optional module (such as fieldbus adapter, I/O extension module and the pulse
encoder interface) is inserted in the optional module slot of the RMIO board (see
Connecting the control cables) and fixed with two screws. See the appropriate
optional module manual for cable connections.

Fibre optic link

A DDCS fibre optic link is provided via the RDCO optional module for PC tools,
master/follower link, NDIO, NTAC, NAIO and fieldbus adapter modules of type Nxxx.
See RDCO User’s Manual for the connections. Observe colouring codes when
installing fibre optic cables. Blue connectors go to blue terminals, and grey
connectors to grey terminals.
When installing multiple modules on the same channel connect them in a ring.

External +24 V power supply for the RMIO board

Refer to chapter External +24 V power supply for the RMIO board.

Electrical installation
 61

Motor control and I/O board (RMIO)

What this chapter contains

This chapter shows
• external control connections to the RMIO board for the the ACS 800 Standard
Application Program (Factory Macro)
• specifications of the inputs and outputs of the board.

To which products this chapter applies

This chapter applies to ACS800 units which employ the RMIO board.

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. 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: 0.4 to 0.8 Nm (0.3 to 0.6 lbf ft)

Note for external power supply

WARNING! If the RMIO board is supplied from an external power source, 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.

Motor control and I/O board (RMIO)

62

External control connections (non-US)

External control cable connections to the RMIO board for the ACS 800 Standard
Application Program (Factory Macro) are shown below. For external control
connections of other application macros and programs, see the appropriate
Firmware Manual.
X20
Terminal block size: 1 VREF- Reference voltage -10 VDC, 1 kohm < RL <
cables 0.3 to 3.3 mm2 (22 to 12 AWG) 2 AGND 10 kohm
Tightening torque: X21
0.2 to 0.4 Nm (0.2 to 0.3 lbf ft) 1 VREF+ Reference voltage 10 VDC, 1 kohm < RL <
2 AGND 10 kohm
3 AI1+ Speed reference 0(2) ... 10 V, Rin >
4 AI1- 200 kohm
5 AI2+ By default, not in use. 0(4) ... 20 mA, Rin =
6 AI2- 100 ohm
7 AI3+ By default, not in use. 0(4) ... 20 mA, Rin =
8 AI3- 100 ohm
rpm 9 AO1+ Motor speed 0(4)...20 mA = 0...motor nom.
10 AO1- speed, RL < 700 ohm
A 11 AO2+ Output current 0(4)...20 mA = 0...motor
12 AO2- nom. current, RL < 700 ohm
X22
1 DI1 Stop/Start
1) Only effective if par. 10.03 is set to 2 DI2 Forward/Reverse 1)
REQUEST by the user. 3 DI3 Not in use
4 DI4 Acceleration & deceleration select 2)
2)
0 = open, 1 = closed 5 DI5 Constant speed select 3)
DI4 Ramp times according to 6 DI6 Constant speed select 3)
0 parameters 22.02 and 22.03 7 +24VD +24 VDC max. 100 mA
1 parameters 22.04 and 22.05 8 +24VD
9 DGND1 Digital ground
3) See par. group 12 CONSTANT
10 DGND2 Digital ground
SPEEDS.
11 DIIL Start interlock (0 = stop) 4)
DI5 DI6 Operation
0 0 Set speed through AI1
X23
1 0 Constant speed 1 1 +24V Auxiliary voltage output, non-isolated,
0 1 Constant speed 2 2 GND 24 VDC 250 mA
1 1 Constant speed 3 X25
1 RO1 Relay output 1: ready
4) See parameter 21.09 START INTRL 2 RO1
FUNC. 3 RO1
X26
1 RO2 Relay output 2: running
2 RO2
3 RO2
X27
1 RO3 Relay output 3: fault (-1)
Fault 2 RO3
3 RO3

Motor control and I/O board (RMIO)

 63

External control connections (US)

External control cable connections to the RMIO board for the ACS 800 Standard
Application Program (Factory Macro US version) are shown below. For external
control connections of other application macros and programs, see the appropriate
Firmware Manual.
X20
Terminal block size: 1 VREF- Reference voltage -10 VDC, 1 kohm < RL <
cables 0.3 to 3.3 mm2 (22 to 12 AWG) 2 AGND 10 kohm
Tightening torque: X21
0.2 to 0.4 Nm (0.2 to 0.3 lbf ft) 1 VREF+ Reference voltage 10 VDC, 1 kohm < RL <
2 AGND 10 kohm
3 AI1+ Speed reference 0(2) ... 10 V, Rin >
4 AI1- 200 kohm
5 AI2+ By default, not in use. 0(4) ... 20 mA, Rin =
6 AI2- 100 ohm
7 AI3+ By default, not in use. 0(4) ... 20 mA, Rin =
8 AI3- 100 ohm
rpm 9 AO1+ Motor speed 0(4)...20 mA = 0...motor nom.
10 AO1- speed, RL < 700 ohm
A 11 AO2+ Output current 0(4)...20 mA = 0...motor
12 AO2- nom. current, RL < 700 ohm
X22
1 DI1 Start ( )
1) Only effective if par. 10.03 is set to 2 DI2 Stop ( )
REQUEST by the user. 3 DI3 Forward/Reverse 1)
4 DI4 Acceleration & deceleration select 2)
2)
0 = open, 1 = closed 5 DI5 Constant speed select 3)
DI4 Ramp times according to 6 DI6 Constant speed select 3)
0 parameters 22.02 and 22.03 7 +24VD +24 VDC max. 100 mA
1 parameters 22.04 and 22.05 8 +24VD
9 DGND1 Digital ground
3)
See par. group 12 CONSTANT
10 DGND2 Digital ground
SPEEDS.
11 DIIL Start interlock (0 = stop) 4)
DI5 DI6 Operation
0 0 Set speed through AI1
X23
1 0 Constant speed 1 1 +24V Auxiliary voltage output, non-isolated,
0 1 Constant speed 2 2 GND 24 VDC 250 mA
1 1 Constant speed 3 X25
1 RO1 Relay output 1: ready
4) See parameter 21.09 START INTRL 2 RO1
FUNC. 3 RO1
X26
1 RO2 Relay output 2: running
2 RO2
3 RO2
X27
1 RO3 Relay output 3: fault (-1)
Fault 2 RO3
3 RO3

Motor control and I/O board (RMIO)

64

RMIO board specifications

Analogue inputs
With Standard Application 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).
The analogue inputs are galvanically isolated as a group.
Isolation test voltage 500 VAC, 1 min
Max. common mode voltage ±15 VDC
between the channels
Common mode rejection ratio > 60 dB at 50 Hz
Resolution 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.
Inaccuracy ± 0.5 % (Full Scale Range) at 25 °C (77 °F). Temperature coefficient: ± 100 ppm/°C
(± 56 ppm/°F), max.

Constant voltage output

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

Auxiliary power output

Voltage 24 VDC ± 10 %, short circuit proof
Maximum current 250 mA (without any optional modules inserted onto slots 1 and 2)

Analogue outputs
Two programmable current outputs: 0 (4) to 20 mA, RL < 700 ohm
Resolution 0.1 % (10 bit)
Inaccuracy ± 1 % (Full Scale Range) at 25 °C (77 °F). Temperature coefficient: ± 200 ppm/°C
(± 111 ppm/°F) max.

Digital inputs
With Standard Application 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 “0”
(high temperature), open circuit “0” (high temperature).
Internal supply for digital inputs (+24 VDC): short circuit proof. An external 24 VDC
supply can be used instead of the internal supply.
Isolation test voltage 500 VAC, 1 min
Logical thresholds < 8 VDC “0”, > 12 VDC “1”
Input current DI1 to DI 5: 10 mA, DI6: 5 mA
Filtering time constant 1 ms

Motor control and I/O board (RMIO)

 65

Relay outputs
Three programmable relay outputs
Switching capacity 8 A at 24 VDC or 250 VAC, 0.4 A at 120 VDC
Minimum continuous current 5 mA rms at 24 VDC
Maximum continuous current 2 A rms
Contact material Silver Cadmium Oxide (AgCdO)
Isolation test voltage 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 24 VDC ± 10 %
Typical current consumption 250 mA
(without optional modules)
Maximum current consumption 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.

Motor control and I/O board (RMIO)

66

Isolation and grounding diagram

(Test voltage: 500 V AC)

X20
1 VREF-
2 AGND
X21
1 VREF+
2 AGND
3 AI1+
4 AI1- Common mode
voltage between
5 AI2+
channels ±15 V
6 AI2-
7 AI3+
8 AI3-

9 AO1+
10 AO1-
11 AO2+
12 AO2-
X22
1 DI1
2 DI2
3 DI3
4 DI4
Jumper J1 settings:
9 DGND1

5 DI5 All digital inputs share a common

J1
6 DI6 ground. This is the default setting.
7 +24VD
8 +24VD Grounds of input groups
11 DIIL DI1…DI4 and DI5/DI6/DIIL
or
are separate (isolation
10 DGND2 voltage 50 V).
X23
1 +24 V
2 GND
X25
1 RO1
2 RO1
3 RO1
X26
1 RO2
2 RO2
3 RO2
X27
1 RO3
2 RO3
3 RO3
(Test voltage:
4 kV AC)
Ground

Motor control and I/O board (RMIO)

 67

Installation checklist

Checklist
Check the mechanical and electrical installation of the drive before start-up. Go
through the checklist below together with another person. Read the Safety
instructions on the first pages of this manual before you work on the unit.

Check
MECHANICAL INSTALLATION
The ambient operating conditions are allowed. (See Mechanical installation, Technical data:
IEC ratings or US tables / NEMA ratings, Ambient conditions.)
The unit is fixed properly on a vertical non-flammable wall. (See Mechanical installation.)
The cooling air will flow freely.
The motor and the driven equipment are ready for start. (See Planning the electrical
installation: Checking the compatibility of the motor, Technical data: Motor connection.)
ELECTRICAL INSTALLATION (See Planning the electrical installation, Electrical installation.)
The +E202 and +E200 EMC filter capacitors are disconnected if the drive is connected to an
IT (ungrounded) system.
The capacitors are reformed if stored over one year (refer to ACS 600/800 Capacitor
Reforming Guide [64059629 (English)].
The drive is grounded properly.
The mains (input power) voltage matches the drive nominal input voltage.
The mains (input power) connections at U1, V1 and W1 and their tightening torques are OK.
Appropriate mains (input power) fuses and disconnector are installed.
The motor connections at U2, V2 and W2 and their tightening torques are OK.
The motor cable is routed away from other cables.
There are no power factor compensation capacitors in the motor cable.
The external control connections inside the drive are OK.
There are no tools, foreign objects or dust from drilling inside the drive.
Mains (input power) voltage cannot be applied to the output of the drive (with bypass
connection).
Drive, motor connection box and other covers are in place.

Installation checklist
68

Installation checklist
 69

Maintenance

What this chapter contains

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.

Maintenance intervals
If installed in an appropriate environment, the drive requires very little maintenance.
This table lists the routine maintenance intervals recommended by ABB.

Maintenance Interval Instruction

Capacitor reforming Every year when stored See Reforming.

Heatsink temperature check Depends on the dustiness of See Heatsink.

and cleaning the environment (every 6 to 12
months)

Cooling fan change Every five years See Fan.

Change of additional cooling Every three years See Additional fan in IP 55

fan in IP 55 units and in IP 21 units and certain IP 21 units
units when included

Frame size R4 and up: Every ten years See Capacitors.

capacitor change

Heatsink
The heatsink fins pick up dust from the cooling air. The drive runs into
overtemperature warnings and faults if the heatsink is not clean. In a “normal”
environment (not dusty, not clean) the heatsink should be checked annually, in a
dusty environment more often.
Clean the heatsink as follows (when necessary):
1. Remove the cooling fan (see section Fan).
2. Blow clean compressed air (not humid) from bottom to top and simultaneously
use a vacuum cleaner at the air outlet to trap the dust. Note: If there is a risk of
the dust entering adjoining equipment, perform the cleaning in another room.
3. Replace the cooling fan.

Maintenance
70

Fan
The cooling fan lifespan of the drive is about 60 000 operating hours. The actual
lifespan depends on the drive usage and ambient temperature. See the appropriate
ACS 800 firmware manual for an actual signal which indicates the hours of usage of
the fan.
Fan failure can be predicted by the increasing noise from fan bearings and the
gradual rise in the heatsink temperature in spite of heatsink cleaning. If the drive is
operated in a critical part of a process, fan replacement is recommended once these
symptoms start appearing. Replacement fans are available from ABB. Do not use
other than ABB specified spare parts.

Fan replacement (R2, R3)

To remove the fan, release the retaining clips. Disconnect the cable. Install the fan in
reverse order.

Bottom view

Maintenance
 71

Fan replacement (R4)

1. Loosen the screws that fasten the fan mounting plate to the frame.
2. Push the fan mounting plate to the left and pull it out.
3. Disconnect the fan power cable.
4. Undo the screws that fasten the fan to the fan mounting plate.
5. Install the new fan in reverse order.

1 1 Bottom view
2

3
View from above fan
plate pulled out

4 4

4 4

Fan replacement (R5, R6)

To remove the fan, undo the fixing screws. Disconnect the cable. Install the fan in
reverse order.
Bottom view (R6)

Bottom view (R5) 2

Maintenance
72

Additional fan in IP 55 units and certain IP 21 units

In IP 21 units, there is an additonal fan in types -0004-2 to 0020-2, -0006-3 to -0030-
3, -0009-5 to -0040-5, -0011-7 to 0060-7.

Replacement (R2, R3)

Remove the front cover. To remove the fan, release the retaining clip (1). Disconnect
the cable (2, detachable terminal). Install the fan in reverse order.

1
2

View from above when front

cover is removed

Replacement (R4, R5)

Remove the front cover. The fan is located on the lower right-hand side of the unit
(R4) or on the right-hand side of the control panel (R5). Lift the fan out and
disconnect the cable. Install the fan in reverse order.

Replacement (R6)
Remove the top cover by lifting it by the rear edge. To remove the fan, release the
retaining clips by pulling the back edge (1) of the fan upwards. Disconnect the cable
(2, detachable terminal). Install the fan in reverse order.

View from above when top

cover is removed

Maintenance
 73

Capacitors
The drive intermediate circuit employs several electrolytic capacitors. Their lifespan
is from 45 000 to 90 000 hours depending on 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
a mains fuse failure or a fault trip. Contact ABB if capacitor failure is suspected.
Replacements for frame size R4 and up 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).

LEDs
This table describes LEDs of the drive.

Where LED When the LED is lit

RMIO board * Red Drive in fault state

Green The power supply on the board is OK.
Control panel mounting platform Red Drive in fault state
(with type code selection +0J400
Green The main +24 V power supply for the control panel and the
only)
RMIO board is OK.

* the LEDs are not visible in frame sizes R2 to R6

Maintenance
74

Maintenance
 75

Technical data

What this chapter contains

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 ratings
The IEC ratings for the ACS800-01 with 50 Hz and 60 Hz supplies are given below.
The symbols are described below the table.
ACS800-01 size Nominal No- Light-overload Heavy-duty use Frame Air flow Heat
overload
ratings use
use size dissipation
Icont.max Imax Pcont.max I2N PN I2hd Phd
A A kW A kW A kW m3/h W
Three-phase supply voltage 208 V, 220 V, 230 V or 240 V
-0001-2 5.1 6.5 1.1 4.7 0.75 3.4 0.55 R2 35 100
-0002-2 6.5 8.2 1.5 6.0 1.1 4.3 0.75 R2 35 100
-0003-2 8.5 10.8 1.5 7.7 1.5 5.7 1.1 R2 35 100
-0004-2 10.9 13.8 2.2 10.2 2.2 7.5 1.5 R2 35 120
-0005-2 13.9 17.6 3 12.7 3 9.3 2.2 R2 35 140
-0006-2 19 24 4 18 4 14 3 R3 69 160
-0009-2 25 32 5.5 24 5,5 19 4 R3 69 200
-0011-2 34 46 7.5 31 7.5 23 5.5 R3 69 250
-0016-2 44 62 11 42 11 32 7.5 R4 103 340
-0020-2 55 72 15 50 11 37 7.5 R4 103 440
-0025-2 72 86 18.5 69 18.5 49 11 R5 168 530
-0030-2 86 112 22 80 22 60 15 R5 168 610
-0040-2 103 138 30 94 22 69 18.5 R5 168 810
-0050-2 141 164 37 132 37 97 30 R6 405 1190
-0060-2 166 202 45 155 45 115 30 R6 405 1190
-0070-2 202 282 55 184 55 141 37 R6 405 1440
Three-phase supply voltage 380 V, 400 V or 415 V
-0003-3 5.1 6.5 1.5 4.7 1.5 3.4 1.1 R2 35 100
-0004-3 6.5 8.2 2.2 5.9 2.2 4.3 1.5 R2 35 120
-0005-3 8.5 10.8 3 7.7 3 5.7 2.2 R2 35 140
-0006-3 10.9 13.8 4 10.2 4 7.5 3 R2 35 160
-0009-3 13.9 17.6 5.5 12.7 5.5 9.3 4 R2 35 200
-0011-3 19 24 7.5 18 7.5 14 5.5 R3 69 250
-0016-3 25 32 11 24 11 19 7.5 R3 69 340
-0020-3 34 46 15 31 15 23 11 R3 69 440
-0025-3 44 62 22 41 18.5 32 15 R4 103 530
-0030-3 55 72 30 50 22 37 18.5 R4 103 610
-0040-3 72 86 37 69 30 49 22 R5 168 810
-0050-3 86 112 45 80 37 60 30 R5 168 990
-0060-3 103 138 55 94 45 69 37 R5 168 1190
-0070-3 141 164 75 132 55 97 45 R6 405 1440
-0100-3 166 202 90 155 75 115 55 R6 405 1940
-0120-3 202 282 110 184 90 141 75 R6 405 2310

Technical data
76

ACS800-01 size Nominal No- Light-overload Heavy-duty use Frame Air flow Heat
overload
ratings use
use size dissipation
Icont.max Imax Pcont.max I2N PN I2hd Phd
A A kW A kW A kW m3/h W
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V
-0004-5 4.9 6.5 2.2 4.5 2.2 3.4 1.5 R2 35 120
-0005-5 6.2 8.2 3 5.6 3 4.2 2.2 R2 35 140
-0006-5 8.1 10.8 4 7.7 4 5.6 3 R2 35 160
-0009-5 10.5 13.8 5.5 10 5.5 7.5 4 R2 35 200
-0011-5 13.2 17.6 7.5 12 7.5 9.2 5.5 R2 35 250
-0016-5 19 24 11 18 11 13 7.5 R3 69 340
-0020-5 25 32 15 23 15 18 11 R3 69 440
-0025-5 34 46 18.5 31 18.5 23 15 R3 69 530
-0030-5 42 62 22 39 22 32 18.5 R4 103 610
-0040-5 48 72 30 44 30 36 22 R4 103 810
-0050-5 65 86 37 61 37 50 30 R5 168 990
-0060-5 79 112 45 75 45 60 37 R5 168 1190
-0070-5 96 138 55 88 55 69 45 R5 168 1440
-0100-5 124 164 75 115 75 88 55 R6 405 1940
-0120-5 157 202 90 145 90 113 75 R6 405 2310
-0140-5 180 282 110 163 110 141 90 R6 405 2810
Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V
-0011-7 13 14 11 11.5 7.5 8.5 5.5 R4 103 300
-0016-7 17 19 15 15 11 11 7.5 R4 103 340
-0020-7 22 28 18.5 20 15 15 11 R4 103 440
-0025-7 25 38 22 23 18.5 19 15 R4 103 530
-0030-7 33 44 30 30 22 22 18.5 R4 103 610
-0040-7 36 54 30 34 30 27 22 R4 103 690
-0050-7 51 68 45 46 37 34 30 R5 168 840
-0060-7 57 84 55 52 45 42 37 R5 168 1010
-0070-7 79 104 75 73 55 54 45 R6 405 1220
-0100-7 93 124 90 86 75 62 55 R6 405 1650
-0120-7 113 172 110 108 90 86 75 R6 405 1960
PDM code: 00096931-C

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.
PN 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.
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.

Technical data
 77

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. If the limit is exceeded, motor
torque and current are automatically restricted. The function protects the input bridge of the drive
against overload.
Note 2: The ratings apply in 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
(3300 ft), or if the ambient temperature exceeds 40 °C (104 °F).
Temperature derating
In the temperature range +40 °C (+104 °F) to +50 °C (+122 °F) the rated output current is decreased
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 =
90 % or 0.90. The output current is then 0.90 · I or 0.90 · I . °C
2N 2hd
Altitude derating
In altitudes from 1000 to 4000 m (3300 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. If the installation site is higher than
2000 m (6600 ft) above sea level, please contact your local ABB distributor or office for further
information.

Technical data
78

Mains cable fuses

Fuses for short-circuit protection of the mains cable are listed below. The fuses also
protect the adjoining equipment of the drive in case of a short-circuit. Check that the
operating time of the fuse is below 0.5 seconds. The operating time depends on
the supply network impedance and the cross-sectional area and length of the supply
cable. See also Planning the electrical installation: Thermal overload and short-
circuit protection. For UL recognized fuses, see US tables.
Note 1: In multicable installations, install only one fuse per phase (not one fuse per conductor).
Note 2: Larger fuses must not be used.
Note 3: Fuses from other manufacturers can be used if they meet the ratings.
ACS800-01 size Input Fuse
current A A2s * V Manufacturer Type IEC size
Three-phase supply voltage 208 V, 220 V, 230 V or 240 V
-0001-2 4.4 10 483 500 ABB Control OFAF000H10 000
-0002-2 5.2 10 483 500 ABB Control OFAF000H10 000
-0003-2 6.7 10 483 500 ABB Control OFAF000H10 000
-0004-2 9.3 16 993 500 ABB Control OFAF000H16 000
-0005-2 12 16 993 500 ABB Control OFAF000H16 000
-0006-2 16 20 1620 500 ABB Control OFAF000H20 000
-0009-2 23 25 3100 500 ABB Control OFAF000H25 000
-0011-2 31 40 9140 500 ABB Control OFAF000H40 000
-0016-2 40 50 15400 500 ABB Control OFAF000H50 000
-0020-2 51 63 21300 500 ABB Control OFAF000H63 000
-0025-2 67 80 34500 500 ABB Control OFAF000H80 000
-0030-2 81 100 63600 500 ABB Control OFAF000H100 000
-0040-2 101 125 103000 500 ABB Control OFAF00H125 00
-0050-2 138 160 200000 500 ABB Control OFAF00H160 00
-0060-2 163 200 350000 500 ABB Control OFAF1H200 1
-0070-2 202 224 420000 500 ABB Control OFAF1H224 1
Three-phase supply voltage 380 V, 400 V or 415 V
-0003-3 4.7 10 483 500 ABB Control OFAF000H10 000
-0004-3 6.0 10 483 500 ABB Control OFAF000H10 000
-0005-3 7.9 10 483 500 ABB Control OFAF000H10 000
-0006-3 10 16 993 500 ABB Control OFAF000H16 000
-0009-3 13 16 993 500 ABB Control OFAF000H16 000
-0011-3 17 20 1620 500 ABB Control OFAF000H20 000
-0016-3 23 25 3100 500 ABB Control OFAF000H25 000
-0020-3 32 40 9140 500 ABB Control OFAF000H40 000
-0025-3 42 50 15400 500 ABB Control OFAF000H50 000
-0030-3 53 63 21300 500 ABB Control OFAF000H63 000
-0040-3 69 80 34500 500 ABB Control OFAF000H80 000
-0050-3 83 100 63600 500 ABB Control OFAF000H100 000
-0060-3 100 125 103000 500 ABB Control OFAF00H125 00
-0070-3 138 160 200000 500 ABB Control OFAF00H160 00
-0100-3 163 200 350000 500 ABB Control OFAF1H200 1
-0120-3 198 224 420000 500 ABB Control OFAF1H224 1

Technical data
 79

ACS800-01 size Input Fuse

current A A2s * V Manufacturer Type IEC size
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V
-0004-5 4.7 10 483 500 ABB Control OFAF000H10 000
-0005-5 5.9 10 483 500 ABB Control OFAF000H10 000
-0006-5 7.7 10 483 500 ABB Control OFAF000H10 000
-0009-5 10.0 16 993 500 ABB Control OFAF000H16 000
-0011-5 12.5 16 993 500 ABB Control OFAF000H16 000
-0016-5 17 20 1620 500 ABB Control OFAF000H20 000
-0020-5 23 25 3100 500 ABB Control OFAF000H25 000
-0025-5 31 40 9140 500 ABB Control OFAF000H40 000
-0030-5 41 50 15400 500 ABB Control OFAF000H50 000
-0040-5 47 63 21300 500 ABB Control OFAF000H63 000
-0050-5 64 80 34500 500 ABB Control OFAF000H80 000
-0060-5 78 100 63600 500 ABB Control OFAF000H100 000
-0070-5 95 125 103000 500 ABB Control OFAF00H125 00
-0100-5 121 160 200000 500 ABB Control OFAF00H160 00
-0120-5 155 200 350000 500 ABB Control OFAF1H200 1
-0140-5 180 200 350000 500 ABB Control OFAF1H200 1
Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V
-0011-7 12 10 150 690 ABB Control OFAA (gG) 00
-0016-7 15 16 1000 690 ABB Control OFAA (gG) 00 / 1
-0020-7 21 20 2000 690 ABB Control OFAA (gG) 00 / 1
-0025-7 24 32 4000 690 ABB Control OFAA (gG) 00 / 1
-0030-7 33 35 5000 690 ABB Control OFAA (gG) 00 / 1
-0040-7 35 50 15000 690 ABB Control OFAA (gG) 00 / 1
-0050-7 52 50 15000 690 ABB Control OFAA (gG) 00 / 1
-0060-7 58 63 20000 690 ABB Control OFAA (gG) 00 / 1
-0070-7 79 80 30000 690 ABB Control OFAA (gG) 00 / 1
-0100-7 91 100 40000 690 ABB Control OFAA (gG) 00 / 1
-0120-7 112 125 70000 690 ABB Control OFAA (gG) 1
PDM code: 00096931-C
* maximum total I2t value for 550 V

Technical data
80

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 60364-5-2/2001). 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 Aluminium cables with concentric
copper shield copper shield
Max. load Cable type Max. load Cable type
current current
A mm2 A mm2
14 3x1.5 61 3x25
20 3x2.5 75 3x35
27 3x4 91 3x50
34 3x6 117 3x70
47 3x10 143 3x95
62 3x16 165 3x120
79 3x25 191 3x150
98 3x35 218 3x185
119 3x50 257 3x240
153 3x70 274 3 x (3x50)
186 3x95 285 2 x (3x95)
215 3x120
249 3x150
284 3x185
PDM code: 00096931-C

Cable entries
Brake resistor, mains and motor cable terminal sizes (per phase), accepted cable
diameters and tightening torques are given below.
Frame U1, V1, W1, U2, V2, W2, R+, R- Earthing PE
size Maximum wire Max. cable Ø Cable Ø Tightening Maximum Tightening
size IP 21 IP 55 torque wire size torque
mm2 mm mm Nm mm2 Nm
R2 16* 21 14...20 1.2...1.5 10 1.5
R3 16* 21 14...20 1.2...1.5 10 1.5
R4 25 29 23...35 2…4 16 3.0
R5 70 35 23...35 15 70 15
R6 185 53 30...45 20...40 95 8

* 16 mm2 rigid solid cable, 10 mm2 flexible stranded cable

Technical data
 81

Dimensions, weights and noise

H1 height with cable connection box, H2 height without cable connection box.
Frame IP 21 IP 55 Noise
size H1 H2 Width Depth Weight Height Width Depth Weight
mm mm mm mm kg mm mm mm kg dB
R2 405 370 165 226 9 528 263 241 16 62
R3 471 420 173 265 12 528 263 273 18 62
R4 607 490 240 274 26 774 377 278 32 62
R5 739 602 265 286 37 775 377 308 50 65
R6 880 700 300 399 67 923 420 420 77 65

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
525/550/575/600/660/690 VAC 3-phase ± 10 % for 690 VAC units
Prospective short-circuit Maximum allowed prospective short-circuit current in the supply is 65 kA in a second
current (IEC 60439-1) providing that the mains cable of the drive is protected with appropriate fuses. US:
65,000 AIC.
Frequency 48 to 63 Hz, maximum rate of change 17 %/s
Imbalance Max. ± 3 % of nominal phase to phase input voltage
Fundamental power factor 0.98 (at nominal load)
(cos phi1)

Motor connection
Voltage (U2) 0 to U1, 3-phase symmetrical, Umax at the field weakening point
Frequency DTC mode: 0 to 3.2 · fFWP. Maximum frequency 300 Hz.

UNmains
fFWP = · fNmotor
UNmotor

fFWP: frequency at field weakening point; UNmains: mains (input power) voltage;
UNmotor: rated motor voltage; fNmotor: rated motor frequency
Frequency resolution 0.01 Hz
Current See section IEC ratings.
Power limit 1.5 · Phd
Field weakening point 8 to 300 Hz
Switching frequency 3 kHz (average). In 690 V units 2 kHz (average).

Technical data
82

Maximum recommended Sizing method Max. motor cable length

motor cable length DTC control Scalar control
according to I2N and I2hd R2 to R3: 100 m (328 ft) R2: 150 m (492 ft)
according to Icont.max in R4 to R6: 300 m (984 ft) R3 to R6: 300 m (984 ft)
ambient temperatures below
30 °C (86 °F)
according to Icont.max in R2: 50 m (164 ft) Note: This applies to units with EMC filter
ambient temperatures above also.
30 °C (86 °F) R3 and R4: 100 m (328 ft)
R5 and R6: 150 m (492 ft)
Additional restriction for units with EMC filtering (type code selections +E202 and +E200):
max. motor cable length is 100 m (328 ft). With longer cables the EMC Directive
requirements may not be fulfilled.

Efficiency
Approximately 98 % at nominal power level

Cooling
Method Internal fan, flow direction from bottom to top.
Free space around the unit See chapter Mechanical installation.

Degrees of protection
IP 21 (UL type 1) and IP 55 (UL type 12). Without connection box and front cover, the unit
must be protected against contact according to IP 2x [see chapter Electrical installation:
Cabinet installation (IP 21, UL type 1)].

Technical data
 83

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]
Air temperature -15 to +50 °C (5 to 122 °F). -40 to +70 °C (-40 to -40 to +70 °C (-40 to
No frost allowed. See section +158 °F) +158 °F)
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: Boards with coating: Boards with coating:
Chemical gases: Class 3C2 Chemical gases: Class 1C2 Chemical gases: Class 2C2
Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2
Atmospheric pressure 70 to 106 kPa 70 to 106 kPa 60 to 106 kPa
0.7 to 1.05 atmospheres 0.7 to 1.05 atmospheres 0.6 to 1.05 atmospheres
Vibration (IEC 60068-2) Max. 1 mm (0.04 in.) Max. 1 mm (0.04 in.) Max. 3.5 mm (0.14 in.)
(5 to 13.2 Hz), (5 to 13.2 Hz), (2 to 9 Hz),
max. 7 m/s2 (23 ft/s2) max. 7 m/s2 (23 ft/s2) max. 15 m/s2 (49 ft/s2)
(13.2 to 100 Hz) sinusoidal (13.2 to 100 Hz) sinusoidal (9 to 200 Hz) sinusoidal
Shock (IEC 60068-2-29) Not allowed Max. 100 m/s2 (330 ft./s2), Max. 100 m/s2 (330 ft./s2),
11 ms 11 ms
Free fall Not allowed 250 mm (10 in.) for weight 250 mm (10 in.) for weight
under 100 kg (220 lb) under 100 kg (220 lb)
100 mm (4 in.) for weight 100 mm (4 in.) for weight
over 100 kg (220 lb) over 100 kg (220 lb)

Technical data
84

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 mm, thickness of coating 100 micrometres
• cast aluminium AlSi (R2 and R3)
• extruded aluminium AlSi (R4 to R6)
Package Corrugated cardboard (frames R2 to R6 and option modules), expanded polystyrene.
Plastic covering of the package: PE-LD, bands PP or steel.
Disposal 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 will be 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.

Applicable standards
The drive complies with the following standards. The compliance with the European Low
Voltage Directive is verified according to standards EN 50178 and EN 60204-1.
• EN 50178 (1997) Electronic equipment for use in power installations
• EN 60204-1 (1997) 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.
• EN 60529: 1991 Degrees of protection provided by enclosures (IP code)
(IEC 60529)
• IEC 60664-1 (1992) Insulation coordination for equipment within low-voltage systems. Part 1: Principles,
requirements and tests.
• EN 61800-3 (1996) + EMC product standard including specific test methods
Amendment A11 (2000)
• UL 508C UL Standard for Safety, Power Conversion Equipment, second edition
• CSA C22.2 No. 14-95 Industrial control equipment

Technical data
 85

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 93/68/EEC).

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 EMC Directive defines the requirements for immunity and emissions of electrical equipment used
within the European Union. The EMC product standard [EN 61800-3 + Amendment A11 (2000)] covers
requirements stated for drives.
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.
Restricted distribution: mode of sales distribution in which the manufacturer restricts the supply of
equipment to suppliers, customers or users who separately or jointly have technical competence in the
EMC requirements of the application of drives.
Unrestricted distribution: mode of sales distribution in which the supply of equipment is not dependent
on the EMC competence of the customer or user for the application of drives.

Compliance with the EMC Directive

The drive complies with the EMC Directive on low-voltage networks with the following provisions.
First environment (restricted distribution)
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
86

Second environment
The requirements of the EMC Directive can be met as follows:
1. The drive is equipped with EMC filter E200. The filter is suitable for TN (earthed) networks only.
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.
If the above listed provisions cannot be met, e.g., the drive cannot be equipped with EMC filter E200
when installed to an IT (unearthed) network, the requirements of the EMC Directive can be met as
follows for restricted distribution:
1. It is ensured that no excessive emission is propagated to neighbouring low-voltage networks. In
some cases, the natural suppression in transformers and cables is sufficient. If in doubt, a 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 Low voltage

Equipment
Drive
(victim)

Equipment Equipment

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.

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
 87

“C-tick” marking
“C-tick” marking is pending as follows.
A “C-tick” mark is attached to each drive in order to verify compliance with the relevant standard
(IEC 61800-3 (1996) – 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.
Restricted distribution: mode of sales distribution in which the manufacturer restricts the supply of
equipment to suppliers, customers or users who separately or jointly have technical competence in the
EMC requirements of the application of drives.
Unrestricted distribution: mode of sales distribution in which the supply of equipment is not dependent
on the EMC competence of the customer or user for the application of drives.

Compliance with IEC 61800-3

First environment (restricted distribution)
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.
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
88

Second environment
The drive complies with the limits of IEC 61800-3 with the following provisions:
1. It is ensured that no excessive emission is propagated to neighbouring low-voltage networks. In
some cases, the natural 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 Low voltage

Equipment
Drive
(victim)

Equipment Equipment

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.

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.
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
 89

US tables

NEMA ratings
The NEMA ratings for the ACS800-U1 with 60 Hz supplies are given below. The
symbols are described below the table. For sizing, derating and 50 Hz supplies, see
IEC ratings.
ACS800-U1 size Imax Normal use Heavy-duty use Frame Air flow Heat
size dissipation
I2N PN I2hd Phd
A A HP A HP ft3/min BTU/Hr
Three-phase supply voltage 208 V, 220 V, 230 V or 240 V
-0001-2 6.5 4.7 1 3.4 0.75 R2 21 350
-0002-2 8.2 6.6 1.5 4.6 1 R2 21 350
-0003-2 10.8 8.1 2 6.6 1.5 R2 21 350
-0004-2 13.8 11 3 7.5 2 R2 21 410
-0006-2 24 21 5 13 3 R3 41 550
-0009-2 32 27 7.5 17 5 R3 41 680
-0011-2 46 34 10 25 7.5 R3 41 850
-0016-2 62 42 15 31 10 R4 61 1150
-0020-2 72 54 20 * 42 15 ** R4 61 1490
-0025-2 86 69 25 54 20 ** R5 99 1790
-0030-2 112 80 30 68 25 ** R5 99 2090
-0040-2 138 104 40 * 80 30 ** R5 99 2770
-0050-2 164 132 50 104 40 R6 238 3370
-0060-2 202 157 60 130 50 ** R6 238 4050
-0070-2 282 192 75 154 60 ** R6 238 4910
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V or 480 V
-0004-5 6.5 4.9 2 3.4 1.5 R2 21 410
-0005-5 8.2 6.2 3 4.2 2 R2 21 480
-0006-5 10.8 8.1 5 5.6 3 R2 21 550
-0009-5 13.8 11 7.5 8.1 5 R2 21 690
-0011-5 17.6 14 10 11 7.5 R2 21 860
-0016-5 24 21 15 15 10 R3 41 1150
-0020-5 32 27 20 21 15 R3 41 1490
-0025-5 46 34 25 27 20 R3 41 1790
-0030-5 62 42 30 34 25 R4 61 2090
-0040-5 72 52 40 37 30 *** R4 61 2770
-0050-5 86 65 50 52 40 R5 99 3370
-0060-5 112 79 60 65 50 R5 99 4050
-0070-5 138 96 75 77 60 R5 99 4910
-0100-5 164 124 100 96 75 R6 238 6610
-0120-5 202 157 125 124 100 R6 238 7890
-0140-5 282 180 150 156 125 R6 238 9600
Three-phase supply voltage 525 V, 575 V, 600 V
-0011-7 14 11.5 10 8.5 5 R4 61 1050
-0016-7 19 15 10 11 10 R4 61 1200
-0020-7 28 20 15 15 10 R4 61 1550
-0025-7 38 23 20 19 15 R4 61 1850
-0030-7 44 30 25 22 20 R4 61 2100
-0040-7 54 34 30 27 25 R4 61 2400
-0050-7 68 46 40 34 30 R5 99 2900
-0060-7 84 52 50 42 40 R5 99 3450
-0070-7 104 73 60 54 50 R6 238 4200
-0100-7 124 86 75 62 60 R6 238 5650
-0120-7 172 108 100 86 75 R6 238 6700
PDM code: 00096931-C

Technical data
90

*
Overload may be limited to 5 % at high speeds (> 90 % speed) by the internal power limit of the
drive. The limitation also depends on motor characteristics and network voltage.
**
Overload may be limited to 40 % at high speeds (> 90 % speed) by the internal power limit of the
drive. The limitation also depends on motor characteristics and network voltage.
***
special 4-pole high-efficiency NEMA motor

Symbols
Nominal ratings
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.
PN typical motor power. The power ratings apply to most 4-pole NEMA rated motors (230 V,
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 1: The ratings apply in ambient temperature of 40 °C (104 °F). In lower temperatures the ratings
are higher (except Imax).

Input cable fuses

The ratings of UL listed fuses for input cable protection are listed below. The fuses
also prevent damage to the adjoining equipment of the drive in case of a short-circuit
inside the drive. Check that the operating time of the fuse is below 0.5 seconds.
The operating time depends on the supply network impedance and the cross-
sectional area and length of the supply cable. The fuses must be of the “non-time
delay” type. See also Planning the electrical installation: Thermal overload and
short-circuit protection.
Note 1: In multicable installations, install only one fuse per phase (not one fuse per conductor).
Note 2: Larger fuses must not be used.
Note 3: Fuses from other manufacturers can be used if they meet the ratings.
Note 4: Circuit breakers are not capable of providing sufficient protection because they are inherently
slower than fuses. Always use fuses with circuit breakers.

Technical data
 91

ACS800-U1 type Input Fuse

current
A A V Manufacturer Type UL class
Three-phase supply voltage 208 V, 220 V, 230 V or 240 V
-0001-2 4.4 10 600 Bussmann JJS-10 T
-0002-2 5.2 10 600 Bussmann JJS-10 T
-0003-2 6.5 10 600 Bussmann JJS-10 T
-0004-2 9.2 10 600 Bussmann JJS-10 T
-0006-2 18 15 600 Bussmann JJS-15 T
-0009-2 24 20 600 Bussmann JJS-20 T
-0011-2 31 25 600 Bussmann JJS-25 T
-0016-2 38 35 600 Bussmann JJS-35 T
-0020-2 49 40 600 Bussmann JJS-40 T
-0025-2 64 50 600 Bussmann JJS-50 T
-0030-2 75 70 600 Bussmann JJS-70 T
-0040-2 102 80 600 Bussmann JJS-80 T
-0050-2 126 100 600 Bussmann JJS-100 T
-0060-2 153 150 600 Bussmann JJS-150 T
-0070-2 190 175 600 Bussmann JJS-175 T
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V
-0004-5 4.1 10 600 Bussmann JJS-10 T
-0005-5 5.4 10 600 Bussmann JJS-10 T
-0006-5 6.9 10 600 Bussmann JJS-10 T
-0009-5 9.8 15 600 Bussmann JJS-15 T
-0011-5 13 20 600 Bussmann JJS-20 T
-0016-5 18 25 600 Bussmann JJS-25 T
-0020-5 24 35 600 Bussmann JJS-35 T
-0025-5 31 40 600 Bussmann JJS-40 T
-0030-5 40 50 600 Bussmann JJS-50 T
-0040-5 52 70 600 Bussmann JJS-70 T
-0050-5 63 80 600 Bussmann JJS-80 T
-0060-5 77 100 600 Bussmann JJS-100 T
-0070-5 94 125 600 Bussmann JJS-125 T
-0100-5 121 150 600 Bussmann JJS-150 T
-0120-5 155 200 600 Bussmann JJS-200 T
-0140-5 179 225 600 Bussmann JJS-225 T
Three-phase supply voltage 525 V, 575 V, 600 V
-0011-7 11 15 600 Bussmann JJS-15 T
-0016-7 14 20 600 Bussmann JJS-20 T
-0020-7 20 30 600 Bussmann JJS-30 T
-0025-7 23 30 600 Bussmann JJS-30 T
-0030-7 32 45 600 Bussmann JJS-45 T
-0040-7 36 45 600 Bussmann JJS-45 T
-0050-7 50 70 600 Bussmann JJS-70 T
-0060-7 57 80 600 Bussmann JJS-80 T
-0070-7 76 100 600 Bussmann JJS-100 T
-0100-7 93 125 600 Bussmann JJS-125 T
-0120-7 116 150 600 Bussmann JJS-150 T

Technical data
92

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 Cable type
current
A AWG/kcmil
18 14
22 12
31 10
44 8
57 6
75 4
88 3
101 2
114 1
132 1/0
154 2/0
176 3/0
202 4/0
224 250 MCM or 2 x 1
251 300 MCM or 2 x 1/0
PDM code: 00096931-C

Cable Entries
Brake resistor, input and motor cable (per phase) terminal sizes, accepted cable
diameters and tightening torques are given below.
Frame U1, V1, W1, U2, V2, W2, R+, R- Earthing PE
size Maximum wire Wire Ø Tightening Maximum Tightening
size (UL type 1) torque wire size torque
AWG in. lbf ft AWG lbf ft
R2 6 0.8 0.9…1.1 8 1.1
R3 6 0.8 0.9...1.1 8 1.1
R4 4 1.14 1.5…3.0 5 2.2
R5 2/0 1.39 11.1 2/0 11.1
R6 350 MCM 2.09 14.8...29.5 4/0 5.9

Technical data
 93

Dimensions and weights

H1 height with gland box, H2 height without gland box.
Frame UL type 1 UL type 12
size H1 H2 Width Depth Weight Height Width Depth Weight
in. in. in. in. lb in. in. in. lb
R2 15.96 14.57 6.50 8.89 20 20.78 10.35 9.49 34
R3 18.54 16.54 6.81 10.45 26 20.78 10.35 10.74 41
R4 23.87 19.29 9.45 10.79 57 30.49 14.84 10.94 71
R5 29.09 23.70 10.43 11.26 82 30.49 14.84 12.14 110
R6 34.65 27.56 11.81 15.75 148 36.34 16.52 16.54 170

UL/CSA markings
Units of UL type 1 are UL and CSA marked. The UL and CSA markings are pending for units of UL type
12.
UL
The drive is suitable for use on a circuit capable of delivering not more than 65 kA rms symmetrical
amperes at the drive nominal voltage (600 V maximum for 690 V units).
The drive provides overload protection in accordance with the National Electrical Code (US). See
ACS 800 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. This can be
applied to a single drive or multiple drives with DC bus connected to allow a sharing of regenerative
energy.

Technical data
94

Technical data
 95

Dimensional drawings

The dimensions are given in milllimetres and [inches].

Dimensional drawings
96

Frame size R2 (IP 21, UL type 1)

64646117-B

Dimensional drawings
 97

Frame size R2 (IP 55)

64646150-B

Dimensional drawings
98

Frame size R3 (IP 21, UL type 1)

64646192-B

Dimensional drawings
 99

Frame size R3 (IP 55)

64646206-C

Dimensional drawings
100

Frame size R4 (IP 21, UL type 1)

64646214-B

Dimensional drawings
 101

Frame size R4 (IP 55)

64647130-B

Dimensional drawings
102

Frame size R5 (IP 21, UL type 1)

64646222-B

Dimensional drawings
 103

Frame size R5 (IP 55)

64647156-B

Dimensional drawings
104

Frame size R6 (IP 21, UL type 1)

64646231-B

Dimensional drawings
 105

Frame size R6 (IP 55)

64684957-C

Dimensional drawings
106

Frame size R2 (UL type 12)

64788051-A

Dimensional drawings
 107

Frame size R3 (UL type 12)

64788078-A

Dimensional drawings
108

Frame size R4 (UL type 12)

64788086-A

Dimensional drawings
 109

Frame size R5 (UL type 12)

64788094-A

Dimensional drawings
110

Frame size R6 (UL type 12)

64788108-A

Dimensional drawings
 111

Resistor braking

What this chapter contains

This chapter describes how to select, protect and wire brake choppers and resistors.
The chapter also contains the technical data.

To which products this chapter applies

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

Availability of brake choppers and resistors for the ACS 800

Frame R2 and R3 drives have a built-in brake chopper as standard equipment. For
frames R4 and up, 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:
Pbr > 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 400-
second 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
112

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.,
2
UDC
Pmax <
R
where
Pmax maximum power generated by the motor during braking
UDC 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
1.35 · 1.2 · 690 VDC (when supply voltage is 525 to 690 VAC).
R resistor resistance (ohm)

• 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

ACS 800-01 type Braking power of Brake resistor(s)
the chopper and the
drive
Pbrcont Type R ER PRcont
(kW) (ohm) (kJ) (kW)
230 V units
-0001-2 0.55 SACE08RE44 44 248 1
-0002-2 0.8 SACE08RE44 44 248 1
-0003-2 1.1 SACE08RE44 44 248 1
-0004-2 1.5 SACE08RE44 44 248 1
-0005-2 2.2 SACE15RE22 22 497 2
-0006-2 3.0 SACE15RE22 22 497 2
-0009-2 4.0 SACE15RE22 22 497 2
-0011-2 5.5 SACE15RE13 13 497 2
-0016-2 11 SAFUR90F575 8 1800 4.5
-0020-2 17 SAFUR90F575 8 1800 4.5
-0025-2 23 SAFUR80F500 6 2400 6
-0030-2 28 SAFUR125F500 4 3600 9
-0040-2 33 SAFUR125F500 4 3600 9
-0050-2 45 2xSAFUR125F500 2 7200 18
-0060-2 56 2xSAFUR125F500 2 7200 18
-0070-2 68 2xSAFUR125F500 2 7200 18

Resistor braking
 113

ACS 800-01 type Braking power of Brake resistor(s)

the chopper and the
drive
Pbrcont Type R ER PRcont
(kW) (ohm) (kJ) (kW)
400 V units
-0003-3 1.1 SACE08RE44 44 210 1
-0004-3 1.5 SACE08RE44 44 210 1
-0005-3 2.2 SACE08RE44 44 210 1
-0006-3 3.0 SACE08RE44 44 210 1
-0009-3 4.0 SACE08RE44 44 210 1
-0011-3 5.5 SACE15RE22 22 420 2
-0016-3 7.5 SACE15RE22 22 420 2
-0020-3 11 SACE15RE22 22 420 2
-0025-3 23 SACE15RE13 13 435 2
-0030-3 28 SACE15RE13 13 435 2
-0040-3 33 SAFUR90F575 8 1800 4.5
-0050-3 45 SAFUR90F575 8 1800 4.5
-0060-3 56 SAFUR90F575 8 1800 4.5
-0070-3 68 SAFUR80F500 6 2400 6
-0100-3 83 SAFUR125F500 4 3600 9
-0120-3 113 SAFUR125F500 4 3600 9
500 V units
-0004-5 1.5 SACE08RE44 44 210 1
-0005-5 2.2 SACE08RE44 44 210 1
-0006-5 3.0 SACE08RE44 44 210 1
-0009-5 4.0 SACE08RE44 44 210 1
-0011-5 5.5 SACE08RE44 44 210 1
-0016-5 7.5 SACE15RE22 22 420 2
-0020-5 11 SACE15RE22 22 420 2
-0025-5 15 SACE15RE22 22 420 2
-0030-5 28 SACE15RE13 13 435 2
-0040-5 33 SACE15RE13 13 435 2
-0050-5 45 SAFUR90F575 8 1800 4.5
-0060-5 56 SAFUR90F575 8 1800 4.5
-0070-5 68 SAFUR90F575 8 1800 4.5
-0100-5 83 SAFUR125F500 4 3600 9
-0120-5 113 SAFUR125F500 4 3600 9
-0140-5 135 SAFUR125F500 4 3600 9
690 V units
-0011-7 5.5 SACE08RE44 44.00 248 1
-0016-7 7.5 SACE08RE44 44.00 248 1
-0020-7 11 SACE08RE44 44.00 248 1
-0025-7 15 SACE08RE44 44.00 248 1
-0030-7 18.5 SACE15RE22 22.00 497 2
-0040-7 22 SACE15RE22 22.00 497 2
-0050-7 30 SAFUR90F575 8.00 1800 4.5
-0060-7 37 SAFUR90F575 8.00 1800 4.5
-0070-7 45 SAFUR90F575 8.00 1800 4.5
-0100-7 55 SAFUR80F500 6.00 2400 6
-0120-7 75 SAFUR80F500 6.00 2400 6
PDM code 00096931-C

Pbrcont The drive and the chopper will withstand this continuous braking power. The braking is considered continuous if the braking time
exceeds 30 s.
Note: The braking energy transmitted to the specified resistor(s) in 400 seconds may not exceed ER.
R Resistance value for the listed resistor assembly. Note: This is also the minimum allowed resistance for the braking resistor.
ER 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.
All braking resistors must be installed outside the converter module. The SACE braking resistors are built in an IP 21 metal housing. The
SAFUR braking resistors are built in an IP 00 metal frame.

Resistor braking
114

Optional brake chopper and resistor(s) for the ACS800-02/U2, the

ACS800-04/U4 and the ACS800-07/U7
ACS 800 type Frame Braking power of the chopper and the Brake resistor(s)
size drive
5/60 s 10/60 s 30/60 s Type R ER PRcont
Pbr5 Pbr10 Pbr30 Pbrcont (ohm) (kJ) (kW)
(kW) (kW) (kW) (kW)
400 V units
-0070-3 R6 - - - 68 SAFUR80F500 6 2400 6
-0100-3 R6 - - - 83 SAFUR125F500 4 3600 9
-0120-3 R6 - - - 113 SAFUR125F500 4 3600 9
-0140-3 R7 135 135 100 80 SAFUR200F500 2.70 5400 13.5
-0170-3 R7 165 150 100 80 SAFUR200F500 2.70 5400 13.5
-0210-3 R7 165 150 100 80 SAFUR200F500 2.70 5400 13.5
-0260-3 R8 240 240 240 173 2XSAFUR210F575 1.70 8400 21
-0320-3 R8 300 300 300 143 2xSAFUR200F500 1.35 10800 27
-0400-3 R8 375 375 273 130 4xSAFUR125F500 1.00 14400 36
-0440-3 R8 473 355 237 120 4xSAFUR210F575 0.85 16800 42
-0490-3 R8 500 355 237 120 4xSAFUR210F575 0.85 16800 42
500 V units
-0100-5 R6 - - - 83 SAFUR125F500 4 3600 9
-0120-5 R6 - - - 113 SAFUR125F500 4 3600 9
-0140-5 R6 - - - 135 SAFUR125F500 4 3600 9
-0170-5 R7 165 132 2) 120 80 SAFUR200F500 2.70 5400 13.5
-0210-5 R7 198 132 2) 120 80 SAFUR200F500 2.70 5400 13.5
-0260-5 R7 198 1) 132 2) 120 80 SAFUR200F500 2.70 5400 13.5
-0270-5* R8 240 240 240 240 2xSAFUR125F500 2.00 7200 18
-0300-5* R8 280 280 280 280 2xSAFUR125F500 2.00 7200 18
-0320-5 R8 300 300 300 300 2xSAFUR125F500 2.00 7200 18
-0400-5 R8 375 375 375 234 2XSAFUR210F575 1.70 8400 21
-0440-5 R8 473 473 450 195 2xSAFUR200F500 1.35 10800 27
-0490-5 R8 480 480 470 210 2xSAFUR200F500 1.35 10800 27
-0550-5 R8 600 400 4) 300 170 4xSAFUR125F500 1.00 14400 36
-0610-5 R8 600 3) 400 4) 300 170 4xSAFUR125F500 1.00 14400 36
690 V units
-0070-7 R6 - - - 45 SAFUR90F575 8.00 1800 4.5
-0100-7 R6 - - - 55 SAFUR80F500 6.00 2400 6
-0120-7 R6 - - - 75 SAFUR80F500 6.00 2400 6
-0140-7 R7 125 5) 110 90 75 SAFUR80F500 6.00 2400 6
-0170-7 R7 125 6) 110 90 75 SAFUR80F500 6.00 2400 6
-0210-7 R7 125 6) 110 90 75 SAFUR80F500 6.00 2400 6
-0260-7 R7 135 7) 120 100 80 SAFUR80F500 6.00 2400 6
-0320-7 R8 300 300 300 260 SAFUR200F500 2.70 5400 13.5
-0400-7 R8 375 375 375 375 SAFUR200F500 2.70 5400 13.5
-0440-7 R8 430 430 430 385 SAFUR200F500 2.70 5400 13.5
-0490-7 R8 550 400 315 225 2xSAFUR125F500 2.00 7200 18
-0550-7 R8 550 400 315 225 2xSAFUR125F500 2.00 7200 18
-0610-7 R8 550 400 315 225 2xSAFUR125F500 2.00 7200 18
PDM code 00096931-C

Pbr5 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.
Pbr10 The drive and the chopper will withstand this braking power for 10 seconds per minute.
Pbr30 The drive and the chopper will withstand this braking power for 30 seconds per minute.
Pbrcont 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.

Resistor braking
 115

R Resistance value for the resistor assembly. Note: This is also the minimum allowed resistance for the braking resistor.
ER 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.

* ACS800-U7 types only

1)
240 kW possible if ambient temperature is below 33 °C (91 °F)
2) 160 kW possible if ambient temperature is below 33 °C (91 °F)
3)
630 kW possible if ambient temperature is below 33 °C (91 °F)
4)
450 kW possible if ambient temperature is below 33 °C (91 °F)
5) 135 kW possible if ambient temperature is below 33 °C (91 °F)
6)
148 kW possible if ambient temperature is below 33 °C (91 °F)
7)
160 kW possible if ambient temperature is below 33 °C (91 °F)

Combined braking cycles for R7:

Examples
Pbr max 5 s or 10 s

Pbr5 or Pbr10
Pbr30

Pbrcont

No braking 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 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 t
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 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.

Resistor braking
116

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.

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, two-
conductor 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

OFF
Fuses 2

1 3 5 13 3

ON
2 4 6 14 4

ACS 800
U1 V1 W1

Q Thermal switch (standard

in ABB resistors)

K1

Resistor braking
 117

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 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.
With Standard Application 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 DI1
2 DI2
3 DI3
4 DI4
5 DI5
6 DI6
7 +24V
Thermal switch (standard 8 +24V
in ABB resistors) 9 DGND
Q
10 DGND
11 DIIL

For other application 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 Application 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.

Resistor braking
118

For settings of other application programs, see the appropriate firmware manual.

Resistor braking
 119

External +24 V power supply for the RMIO board

What this chapter contains

This chapter describes how to connect external +24 V power supply for the RMIO
board.

When to use
External +24 V power supply for the RMIO board is recommended if
• the application requires fast start after connecting the input power supply
• fieldbus communication is required when the input power supply is disconnected.
For current consumption of the RMIO board, see chapter Motor Control and I/O
Board (RMIO).

Parameter settings
In Standard Application Program, set parameter 16.9 CTRL BOARD SUPPLY to
EXTERNAL 24V if the RMIO board is powered from an external supply.

External +24 V power supply for the RMIO board

120

Connecting +24 V external power supply

1. Break off the tab covering the +24 VDC power input connector with pliers.
2. Lift the connector upwards.
3. Disconnect the wires from the connector (keep the connector for later use).
4. Isolate the ends of the wires individually with insulating tape.
5. Cover the isolated ends of the wires with insulating tape.
6. Push the wires inside the skeleton.
7. Connect the wires of the +24 V external power supply to the disconnected
connector: + wire to terminal 1 and - wire to terminal 2.
8. Plug the connector in.

Frame sizes R2 to R4 Frame sizes R5 and R6

4
4
3

External +24 V power supply for the RMIO board

 121

5 6 7

External +24 V power supply for the RMIO board

122

External +24 V power supply for the RMIO board

 Dimensional drawings 17.6.2003
3AFE 64382101 Rev D EN
EFFECTIVE: 17.6.2003

ABB Oy ABB Inc.

AC Drives Drives and Power Electronics
P.O. Box 184 16250 West Glendale Drive
FIN-00381 HELSINKI New Berlin, WI 53151
FINLAND USA
Telephone +358 10 22 11 Telephone 262 785-3200
Fax +358 10 22 22681 800 243-4384
Internet http://www.abb.com Fax 262 780-5135