ACS800

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

HARDWARE MANUALS (appropriate manual is included in the

delivery)

ACS800-01/U1 Hardware Manual 0.55 to 160 kW (0.75 to 200 HP)

3AFE64382101 (English)
ACS800-01/U1/04 Marine Supplement 0.55 to 160 kW (0.75 to
200 HP) 3AFE64291275 (English)
ACS800-11/U11 Hardware Manual 5.5 to 110 kW (7.5 to 125 HP)
3AFE68367883 (English)
ACS800-31/U31 Hardware Manual 5.5 to110 kW (7.5 to 125 HP)
3AFE68599954 (English)
ACS800-02/U2 Hardware Manual 90 to 500 kW (125 to 600 HP)
3AFE64567373 (English)
ACS800-04/U4 Hardware Manual 0.55 to 160 kW (0.75 to 200 HP)
3AFE68372984 (English)
ACS800-04/04M/U4 Hardware Manual 45 to 560 kW (60 to
600 HP) 3AFE64671006 (English)
ACS800-04/04M/U4 Cabinet Installation 45 to 560 kW (60 to
600 HP) 3AFE68360323 (English)
ACS800-07/U7 Hardware Manual 45 to 560 kW (50 to 600 HP)
3AFE64702165 (English)
ACS800-07/U7 Dimensional Drawings 45 to 560 kW (50 to
600 HP) 3AFE64775421
ACS800-07 Hardware Manual 500 to 2800 kW
3AFE64731165 (English)
ACS800-17 Hardware Manual 55 to 2500 kW (75 to 2800 HP)
3AFE68397260 (English)
ACS800-37 Hardware Manual 55 to 2700 kW (75 to 3000 HP)
3AFE68557925 (English)

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

FIRMWARE MANUALS, SUPPLEMENTS AND GUIDES

(appropriate documents are included in the delivery)

Standard Control Program Firmware Manual

3AFE64527592 (English)
System Control Program Firmware Manual
3AFE64670646 (English)
Control Program Template Firmware Manual
3AFE64616340 (English)
Master/Follower 3AFE64590430 (English)
Pump Control Program Firmware Manual
3AFE68478952 (English)
Extruder Control Program Supplement 3AFE64648543 (English)
Centrifuge Control Program Supplement 3AFE64667246 (English)
Traverse Control Program Supplement 3AFE64618334 (English)
Crane Control Program Firmware Manual 3BSE11179 (English)
Adaptive Programming Application Guide
3AFE64527274 (English)

OPTION MANUALS (delivered with optional equipment)

Fieldbus Adapters, I/O Extension Modules etc.

ACS800-04 and ACS800-04M Drive Modules
45 to 560 kW
ACS800-U4 Drive Modules
60 to 600 HP

Cabinet Installation

3AFE68360323 Rev B EN
EFFECTIVE: 14.2.2008

© 2008 ABB Oy. All Rights Reserved.

 5

Table of contents

ACS800 Single Drive Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Table of contents

About this manual

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Other related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Categorization according to the frame size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Categorization according to the plus code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Installation, commissioning and operating flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

The ACS800-04/U4 and ACS800-04M

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
The ACS800-04/U4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
The ACS800-04M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Example configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Main circuit and control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Connections of the Drive Control Unit (RDCU) in frame sizes R7 and R8 . . . . . . . . . . . . . . . . 21
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Planning the cabinet installation

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Cabinet construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Disposition of the devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Layout examples, door closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Layout examples, door open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Grounding of mounting structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Busbar material and joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Table of contents
6

Cabinet cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Cabinet cooling data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
IP 22 cabinet with no extra fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
IP 54 cabinet with an extra fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Preventing the recirculation of hot air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Outside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Cubicle heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Required free space around the drive module for cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Free space at the top of the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Free space around units with busbars on the long side (bookshelf mounting +H354) . . . . . . . 31
Free space around units with busbars on the short side (flat mounting +H360) . . . . . . . . . . . 32
When the drive module is installed in another position than vertically . . . . . . . . . . . . . . . . . . . . . . 33
Drive module of frame size R7 on its side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Drive module of frame size R7 on its back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
EMC requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Grounding of cable shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installing the Drive Control Unit (RDCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Fastening of the control panel (CDP312R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Installing the control panel directly on the cabinet door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Control Panel Mounting Platform RPMP-11/13 (+J410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Control Panel Holder RPMP-21 (+J413) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Mechanical installation of pre-assembled units (ACS800-04/U4)

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Moving and unpacking the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Fasten the module to the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Clamping the pedestal with the outside brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Fasten the terminals to the busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
View of output busbar connections of frame size R7 (DC and brake busbars included) . . . 43
View of output busbar connections of frame size R8 (DC and brake busbars included) . . 44
User connections of Prevention of Unexpected Start (+Q950) . . . . . . . . . . . . . . . . . . . . . . . . . 44

Mechanical installation of non-pre-assembled units (ACS800-04M)

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
How to read this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Units with bottom exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Units with pedestal and busbars on the long side (+H354, bookshelf mounting) . . . . . . . . . . . 45
Units with pedestal and busbars on the short side (+H360, flat mounting) . . . . . . . . . . . . . . . . 45
Required tools and tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Moving and unpacking the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Table of contents
 7

Frame size R7 units with bottom exit (+H352) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Assembling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Fastening the spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Fastening the top entry busbar and bottom exit shrouds (+B060) . . . . . . . . . . . . . . . . . . . . . . . 55
Top entry busbar shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Bottom exit shroud ....................................................... 56
Units with pedestal and busbars on the long side (+H354, bookshelf mounting) . . . . . . . . . . . . . . 57
Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Item packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Item packages of frame size R7 with busbars on the long side . . . . . . . . . . . . . . . . . . . . . . . 58
Item packages of frame size R8 with busbars on the long side . . . . . . . . . . . . . . . . . . . . . . 64
Assembling procedure for units with busbars on the long side (+H354) . . . . . . . . . . . . . . . . . . . . . 73
Working order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Connecting the DC busbars to the pedestal (+H356 and +H363 only) . . . . . . . . . . . . . . . . . . . 76
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Photos of frame size R7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Photos of frame size R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Busbars to the left- or right-hand side of the module? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Swapping the busbars of the pedestal to the other side . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Optional selection +H363 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Fastening the pedestal to the cabinet base (not for wall-mounted units) . . . . . . . . . . . . . . . . . . 80
Clamping the pedestal with the outside brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Fastening the pedestal through the holes inside the pedestal . . . . . . . . . . . . . . . . . . . . . . . . 80
Fastening the drive module by top to the cabinet frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Fastening the drive module to wall (wall-mounted units only, not for base-mounted units) . . . . 81
Requirements for protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Requirements for the wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Fastening the output busbars and PE terminal and sliding the module in . . . . . . . . . . . . . . . . . 86
View of output busbar connections of frame size R7 (DC and brake busbars included) . . . 87
View of output busbar connections of frame size R8 (DC and brake busbars included) . . . 88
Fastening the drive module to the pedestal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Fastening the shrouds in frame size R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Top entry busbar shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Vertical busbar shroud .................................................... 90
Units with pedestal and busbars on the short side (+H360, flat mounting) . . . . . . . . . . . . . . . . . . . 91
Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Item packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Item packages of frame size R7 with busbars on the short side . . . . . . . . . . . . . . . . . . . . . . 92
Item packages of frame size R8 with busbars on the short side . . . . . . . . . . . . . . . . . . . . . 98

Table of contents
8

Assembling procedure for units with busbars on the short side (+H360) . . . . . . . . . . . . . . . . . . . 104
Working order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Swapping the pedestal output busbars to the left-hand side . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Connecting the DC busbars to the pedestal (+H360 +H356 only) . . . . . . . . . . . . . . . . . . . . . . 107
Required parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Preparing the adapter (+H360 +H356 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Required parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Fastening the adapter to the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Fastening the drive module to the pedestal via the adapter . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Connecting the output busbars on the short side of the module . . . . . . . . . . . . . . . . . . . . . . . 111
Procedure for frame size R7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Procedure frame size R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Checking the installation

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Cabinet construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Instrumentation, busbars and cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Groundings and protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Labels, switches, fuses and doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Dimensional drawings
Frame size R7 without pedestal (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Frame size R7 with bottom exit (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Frame size R7 with bottom exit and top entry and bottom exit shrouds (mm) . . . . . . . . . . . . . . 122
Frame size R7 with busbars on the left side (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Frame size R7 with DC busbars on both sides (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Frame size R7 pedestal busbars on the long side (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Frame size R7 with busbars on the short side (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Frame size R8 without pedestal (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Frame size R8 with busbars on the left side (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Frame size R8 with top entry and vertical busbar shrouds (mm) . . . . . . . . . . . . . . . . . . . . . . . . . 129
Frame size R8 with busbars on both sides (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Frame size R8 pedestal busbars on the long side (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Frame size R8 with busbars on the short side (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Wall mounting spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Frame size R7 bottom exit kit (+H352) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Frame size R7 top entry busbar shroud and bottom exit shroud (+B060) . . . . . . . . . . . . . . . . . . 135
Control Panel Holder RPMP-21 (+J413) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Drive Control Unit (RDCU-02) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Table of contents
 9

Dimensional drawings (USA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Frame size R7 without pedestal (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Frame size R7 with bottom exit (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Frame size R7 with bottom exit and top entry and bottom exit shrouds (inches) . . . . . . . . . . . 141
Frame size R7 with busbars on the left side (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Frame size R7 with busbars on both sides (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Frame size R7 pedestal busbars on the long side (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Frame size R7 with busbars on the short side (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Frame size R8 without pedestal (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Frame size R8 with busbars on the left side (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Frame size R8 with top entry and vertical busbar shrouds (inches) . . . . . . . . . . . . . . . . . . . . . 148
Frame size R8 with busbars on both sides (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Frame size R8 pedestal busbars on the long side (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Frame size R8 with busbars on the short side (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Circuit diagrams
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Assembly drawings
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Adding UDC+/R+, UDC- and R- busbars to the pedestal (frame size R7, +H356+H360) . . . . . . 156
Adding UDC+/R+, UDC- and R- busbars to the adapter (frame size R7, +H356+H360) . . . . . . . 157
Adding UDC+/R+, UDC- and R- busbars to the pedestal (frame size R8, +H356+H360) . . . . . . 158
Adding UDC+/R+, UDC- and R- busbars to the adapter (frame size R8, +H356+H360) . . . . . . . 159

Table of contents
10

Table of contents
 11

About this manual

What this chapter contains

This chapter describes the intended audience and contents of the manual. It
contains a flowchart of steps in checking the delivery, installing and commissioning
the drive. The flowchart refers to chapters/sections in this manual and other
manuals.

Target audience
This manual is intended for people who plan the installation, and install the drive
module into a user-defined cabinet. Read the manual before the installation work.
The reader is expected to know the fundamentals of electricity, wiring, electrical
components and electrical schematic symbols.
The manual is written for readers worldwide. Both SI and imperial units are shown.
Special US instructions for installations within the United States that must be
installed per the National Electrical Code and local codes are marked with (US).

Safety

WARNING! Follow the safety instructions given in ACS800-04/04M/U4 Hardware

Manual [3AFE64671006 (English)] 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.

Other related manuals

See ACS800-04/04M/U4 Hardware Manual [3AFE64671006 (English)] for
information concerning the drive module such as
• safety
• planning the electrical installation
• electrical installation
• motor control and I/O board (RMIO)
• maintenance
• technical data
• resistor braking.

About this manual

12

For installation instructions of optional equipment, see their manuals.

For example installations in Rittal TS 8 cabinet, refer to ACS800-04/U4 Rittal TS 8
Cabinet Installation [3AFE68372330 (English)].

Categorization according to the frame size

The instructions, technical data and dimensional drawings which concern only
certain frame sizes are marked with the symbol of the frame size R7 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 in ACS800-04/04M/U4
Hardware Manual [3AFE64671006 (English)].

Categorization according to the plus code

The instructions, technical data and dimensional drawings which concern only
certain optional selections are marked with plus codes, e.g. +E210 or +H354. The
options included in the drive can be identified from the plus codes visible on the type
designation label of the drive. The plus code selections are listed in chapter The
ACS800-04/U4 and ACS800-04M under Type code.

Contents
The chapters of this manual are briefly described below.
About this manual introduces this manual.
The ACS800-04/U4 and ACS800-04M describes the drive module.
Planning the cabinet installation instructs on general cabinet design, gives layout
examples, free space requirements around the drive module for cooling and cabinet
cooling data.
Mechanical installation of pre-assembled units (ACS800-04/U4) instructs how to
mount a pre-assembled drive module into a cabinet.
Mechanical installation of non-pre-assembled units (ACS800-04M) instructs how to
assemble the drive from the assembly kits.
Checking the installation helps in checking the mechanical and electrical installation
of the drive.
Dimensional drawings contains the dimensional drawings of the drive modules.
Circuit diagrams shows an example circuit diagram for employing the Prevention of
Unexpected Start function (+Q950).
Assembly drawings contains a few step-by-step assembly drawings.

About this manual

 13

Installation, commissioning and operating flowchart

Task Chapters in this manual Chapters in ACS800-04/04M/U4

Hardware Manual
[3AFE64671006 (English)]

Identify the frame size of your drive, R7 or R8. - Technical data / IEC ratings or
NEMA ratings

Plan the installation. Planning the cabinet installation Technical data

Check the ambient conditions, ratings, If optional equipment is included, see Planning the electrical installation
required cooling air flow, input power its manuals.
connection, compatibility of the motor, motor
connection, and other technical data.

Unpack and check the units. Mechanical installation of pre- -

Check that all necessary optional modules assembled units (ACS800-04/U4) or
and equipment are present and correct. Mechanical installation of non-pre-
assembled units (ACS800-04M)
Only intact units may be started up.
If the converter has been non-
operational for more than one year,
the converter DC link capacitors need
to be reformed. Ask ABB for
instructions.

Assemble and install the drive module into the Mechanical installation of pre-
cabinet. assembled units (ACS800-04/U4) or
Mechanical installation of non-pre-
assembled units (ACS800-04M)

Install the RDCU drive control unit. - See RDCU Drive Control Unit
Hardware Manual
[3AFE64636324 (English)]

Check the installation. Checking the installation -

Electrical installation - Safety, Planning the electrical

installation, Electrical installation,
Maintenance, Technical Data,
Resistor braking

Commissioning and operating the drive - See the appropriate firmware

manual.

About this manual

14

Product and service inquiries

Address any inquiries about the product to your local ABB representative, quoting
the type code and serial number of the unit in question. A listing of ABB sales,
support and service contacts can be found by navigating to www.abb.com/drives and
selecting Drives – World wide service contacts on the right pane.

Product training
For information on ABB product training, navigate to www.abb.com/drives and select
Drives – Training courses on the right pane.

Providing feedback on ABB Drives manuals

Your comments on our manuals are welcome. Go to www.abb.com/drives, then
select successively Drives – Document Library – Manuals feedback form on the right
pane.

About this manual

 15

The ACS800-04/U4 and ACS800-04M

What this chapter contains

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

The ACS800-04/U4
The ACS800-04/U4 is an IP 00 drive module for controlling AC motors. It is to be
installed into a cabinet by the customer with base or wall fastening. The input cable
terminals are located at the top of the unit whereas the motor cable terminals are
located at the left- or right-hand side of the unit. The unit is delivered pre-assembled
with mounting pedestal and output busbars.

Slots for cables going to the RMIO board in the RDCU unit. The cables are coiled
on the top of the module.

Fastening points

Input cable terminals

Fastening points

Terminal block for user connection Fastening points

of optional Prevention of
Unexpected Start (+Q950). See
ACS800-04/04M/U4 Cabinet
Installation [3AFE68360323
(English)] chapter Circuit diagrams.
Front cover Drive Control Unit
Motor cable terminals (RDCU)

Optional brake and DC

busbars and terminals

Additional holes for fastening the cable

PE terminal
terminals

Alternative output cable

terminals (when no
vertical busbars are used) Pedestal

Fastening bracket

The ACS800-04/U4 and ACS800-04M

16

The ACS800-04M
The ACS800-04M is delivered as non-pre-assembled kits, which provide more
alternatives in assembling the units than the basic ACS800-04.

Example configurations
Frame size R7

Motor and brake busbars on the Motor and brake busbars on the Output busbars on the short
left-hand long side of the module right-hand long side of the module side of the module
and DC busbars on the right-hand and DC busbars on the left-hand
side side

Frame size R8

Drive Control Unit

(RDCU)

Frame size R7 with bottom exit

(optional top entry busbar
shroud and bottom exit shroud
included). Output busbars are
located at the base of the
module.

Output busbars on the short

side of the module

The ACS800-04/U4 and ACS800-04M

 17

Type designation label

The type designation label includes an IEC and NEMA rating, C-UL US, and CSA
markings, a type code and a serial number, which allow individual recognition of
each unit. The first digit of the serial number refers to the manufacturing plant. The
next four digits refer to the 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 located on the front cover and the serial number label
inside the unit. Example labels are shown below.

The ACS800-04/U4 and ACS800-04M

18

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. ACS800-04-
0170-5). The optional selections are given thereafter, separated by plus signs (e.g.
+E202). The main selections are described below. Not all selections are available for
all types. For more information, refer to ACS800 Ordering Information (EN code:
64556568, available on request).

Type code for ACS800-04 and ACS800-U4 pre-assembled units

Selection Alternatives
Product series ACS800 product series
Type 04 Drive module. When no options are selected: 6-pulse diode input bridge, IP 00, top
entry, side exit, RDCU drive control unit, no control panel, no EMC filter, Standard
Control Program, boards without coating, pedestal with output on the long side, output
busbar set for motor, base and wall mounting brackets, one set of manuals. Pre-
assembled unit.
U4 Drive module (USA). When no options are selected: 6-pulse diode bridge, open
chassis, top entry, side exit, no control panel, no EMC filter, US version of the
Standard Control Program (three-wire start/stop as default setting), common mode
filter in frame size R8, boards without coating, pedestal with output on the long side,
output busbar set for motor, base and wall mounting brackets, one set of manuals.
Pre-assembled unit.
Size Refer to Technical data: IEC ratings or NEMA ratings in Hardware Manual [3AFE64671006
(English)].
Voltage range 2 208/220/230/240 VAC
(nominal rating in bold) 3 380/400/415 VAC
5 380/400/415/440/460/480/500 VAC
7 525/575/600/690 VAC
+ options
Resistor braking D150 brake chopper and busbars for brake resistor and DC connection
Filter E210 EMC/RFI filter for second environment TN/IT (grounded/ungrounded) system
E208 common mode filter
Pedestal and output 0H354 no pedestal
busbars
Control panel J400 control panel including a 3-metre panel connection cable
J410 RPMP-11 control panel mounting platform kit including a 3-metre panel connection
cable but no control panel
J413 RPMP-21 control panel holder
Fieldbus K... Refer to ACS800 Ordering Information (EN code: 64556568).
I/O L...
Control program N...
Language of manual R...
Specialities P901 coated boards
Safety features Q950 Prevention of Unexpected Start, 500 mm (19.68 in.) cable outside the drive module in
frame size R7, 600 mm (23.62 in.) cable outside the drive module in frame size R8.

The ACS800-04/U4 and ACS800-04M

 19

Type code for ACS800-04M non-pre-assembled units (delivered as kits)

Selection Alternatives
Product series ACS800 product series
Type 04M Drive module. When no options are selected: 6-pulse diode input bridge, IP 00, top
entry, RDCU drive control unit, Standard Control Program, boards without coating,
one set of manuals. No pedestal, no output busbars, no control panel, no EMC filter.
Delivered as kits.
Size Refer to Technical data: IEC ratings in Hardware Manual [3AFE64671006 (English)].
Voltage range 2 208/220/230/240 VAC
(nominal rating in bold) 3 380/400/415 VAC
5 380/400/415/440/460/480/500 VAC
7 525/575/600/690 VAC
+ options
Shrouds B060 Frame size R7: clear plastic shrouds for bottom exit kit (+H352) and input terminals.
Frame size R8: clear plastic shrouds for vertical busbars and input terminals in
bookshelf mounting (+H354)
Resistor braking D150 brake chopper
Filter E202 EMC/RFI filter for first environment TN (grounded) system, restricted (the A limits)
E210 EMC/RFI filter for second environment TN/IT (grounded/ungrounded) system
E208 common mode filter
Pedestal and output H352 bottom exit kit for frame size R7
busbars H354 pedestal with output on the long side (bookshelf)
H355 vertical busbars and support brackets for AC output connection
H356 pedestal (and adapter with +H360) busbar kit for brake resistor and DC connection
H360 pedestal with output on the short side (flat)
H362 vertical busbars (and support brackets with +H360) for DC output connection
H363 busbar kit for DC and brake outputs on different long sides of the pedestal (+H356
required, not available for +H360)
Control panel J400 control panel including a 3-metre panel connection cable
J410 RPMP-11 control panel mounting platform kit including a 3-metre panel connection
cable but no control panel
J413 RPMP-21 control panel holder
Fieldbus K... Refer to ACS800 Ordering Information (EN code: 64556568).
I/O L...
Control program N...
Language of manual R...
Specialities P901 coated boards
Safety features Q950 Prevention of Unexpected Start, 500 mm (19.68 in.) cable outside the drive module in
frame size R7, 600 mm (23.62 in.) cable outside the drive module in frame size R8.

The ACS800-04/U4 and ACS800-04M

20

Main circuit and control interfaces

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, RRIA or
RTAC

External control via Optional module 2: RTAC, RAIO, RRIA

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

Drive
Capacitor bank
Rectifier Inverter
U1
U2
AC supply V1 V2 Motor output
W1
W2

Brake chopper
(optional)

R- UDC+ UDC-
R+

The ACS800-04/U4 and ACS800-04M

 21

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

ACS800-04
drive module
Protective tube

AINT
3 m (118 in.)

80 (3.1
ø 4.5 (0.18”) 5”) 80 (3.15”)
Shield

APOW

2100 mm (83 in.)

Shielded 6-pin
modular connector To RMIO
Control panel mounting platform
kit (RPMP-11, optional)

3 m (118 in.)
Drive control unit
RDCU which
contains motor
External control connections control and I/O
to RMIO board board RMIO

Control panel
CDP312R (optional)

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 ACS800-04/U4 and ACS800-04M

22

Printed circuit boards

The drive contains the following printed circuit boards as standard:
• main circuit board (AINT)
• motor control and I/O board (RMIO) with a fibre optic link to the AINT board
• input bridge control board (AINP)
• input bridge protection board (AIBP) which includes snubbers for the thyristors
and varistors
• power supply board (APOW)
• gate driver control board (AGDR)
• diagnostics and panel interface board (ADPI)
• brake chopper control board (ABRC) with option +D150

Motor control
The motor control is based on the Direct Torque Control (DTC) method. Two phase
currents and DC link voltage are measured and used for the control. The third phase
current is measured for earth fault protection.

The ACS800-04/U4 and ACS800-04M

 23

Planning the cabinet installation

What this chapter contains

This chapter guides in planning the installation of a converter module into a user-
defined cabinet. The chapter gives free space requirements around the module for
cooling, cabinet cooling data and layout examples. The issues discussed are
essential for the safe and trouble-free use of the drive system.

Note: The installation must always be designed and made according to applicable
local laws and regulations. ABB does not assume any liability whatsoever for any
installation which breaches the local laws and/or other regulations.

Cabinet construction
The cabinet frame must be sturdy enough to carry the weight of the drive
components, control circuitry and other equipment installed in it.
The cabinet must protect the converter module against contact and meet the
requirements for dust and humidity, see chapter Technical data in ACS800-04/04M/
U4 Hardware Manual [3AFE64671006 (English)].

Disposition of the devices

For easy installation and maintenance, a spacious layout is recommended. Sufficient
cooling air flow, obligatory clearances, cables and cable support structures all
require space.
The control boards must not be installed near main circuits or hot parts.
The following sections show a few layout examples. For example layouts in
Rittal TS 8 cabinet, refer to ACS800-04/U4 Rittal TS 8 Cabinet Installation
[3AFE68372330 (English)].

Planning the cabinet installation

24

Layout examples, door closed

IP 22 IP 54

2c
2b 2a
1a Air inlet for the converter module
1b Air inlet for the other equipment
2a Air outlet for the converter module
2b Air outlet for the other equipment
3 3
2c Air outlet for the converter module and the
other equipment, an extra exhaust fan
4 4 3 Converter control panel (connected to the
5 5 RMIO board in the RDCU unit inside the
cabinet)
4 Contactor control switch and emergency
1a 1a stop switch (connected to the contactor
control circuit inside the cabinet)
5 Operating handle of the disconnector

1a 1a

1b 1b

Roof air flow viewed from top

Planning the cabinet installation

 25

Layout examples, door open

IP 22 IP 54

1 1 1 Supporting frame of the cabinet

2 Air baffles that separate the cool and hot
3 3 areas (leak-proof lead-throughs)
n n 3 Input power cable including the protective
5 2 5 2
conductors to cabinet grounding (PE)
4 Disconnector and fuses
3 3 5 Contactor
8 6 8 6
6 Converter module
7 Motor cable including the grounding
4 4
conductors
8 Drive Control Unit RDCU (includes RMIO
n n board)
3 3
9 External control cables
9 9

PE PE

3 7 3 7

Air flow to the roof Air flow through the module

IP 22 IP 54

Fan

2 2

See also section Required free space around the drive

module for cooling.

WARNING! For units without bottom exit kit (+H352), it is not allowed to connect the
cables directly to the drive module terminals without the pedestal as the lead-
through insulation material is not strong enough to carry the mechanical stress
exerted by the cables.

Planning the cabinet installation

26

Grounding of mounting structures

Make sure any cross-members or shelves on which components are mounted are
properly grounded and the connecting surfaces left unpainted. The drive module will
be grounded to the cabinet frame via its fastening screws.

Busbar material and joints

Tin-plated copper is recommended but aluminium can also be used.
Before joining aluminium busbars, remove the oxide layer and apply suitable anti-
oxidant joint compound.

Tightening torques
The following table applies to grade 8.8 screws (with or without joint compound).
Screw size Torque
M5 3.5 N·m (2.6 lbf·ft)
M6 9 N·m (6.6 lbf·ft)
M8 20 N·m (14.8 lbf·ft)
M10 40 N·m (29.5 lbf·ft)
M12 70 N·m (52 lbf·ft)
M16 180 N·m (133 lbf·ft)

Cabinet cooling
The installation site must be sufficiently ventilated.
The cabinet must have enough free space for the components to ensure sufficient
cooling. Observe the minimum clearances given for each component.
The heat dissipated by cables and other additional equipment must also be
ventilated.
The air inlets and outlets must be equipped with gratings that
• guide the air flow
• protect against contact
• prevent water splashes from entering the cabinet.

Planning the cabinet installation

 27

The drawing below shows two typical cabinet cooling solutions. The air inlet is at the
bottom of the cabinet, while the outlet is at the top, either on the upper part of the
door or on the roof.

Air outlet

Air inlet

The internal cooling fans of the converter modules and reactors/chokes are usually
sufficient to keep the component temperatures low enough in IP 22 cabinets.
In IP 54 cabinets, thick filter mats are used to prevent water splashes from entering
the cabinet. This entails the installation of additional cooling equipment, such as a
hot air exhaust fan.
Arrange the cooling air flow through the converter module so that the requirements
given in chapter Technical data in ACS800-04/04M/U4 Hardware Manual
[3AFE64671006 (English)] are met:
• cooling air flow
Note: The figures apply to continuous nominal load. If the load is cyclic or less than nominal, less
cooling air is required.

• allowed ambient temperature.

See section Cabinet cooling data for:
• allowed temperature rise inside the cabinet
• allowed pressure drop over the cabinet that the module fan can overcome
• air inlet and outlet sizes required for the module cooling and recommended filter
material (if used).

Planning the cabinet installation

28

Cabinet cooling data

IP 22 cabinet with no extra fan
The table below shows the data the IP 22 cabinet should meet to ensure efficient
cooling of the converter module. No extra fan is used. The pressure drop over the
cabinet is the additional counterpressure that the module fan is capable of
overcoming while still maintaining the required air flow through the module.
Frame Temp. rise Pressure drop Cabinet air inlet Min. cabinet air
size Over module Over module Over cabinet Min. size Filter outlet size*
°C Pa Pa mm by Luftfilter mm
R7 30 300 30 288×292+688×521 airTex G150 398×312 (2 pcs)
R8 30 300 45 288×292+688×521 airTex G150 398×312 (2 pcs)
00096931

* size when the outlet is located on the cabinet roof

IP 54 cabinet with an extra fan
The table below shows the data the IP 54 cabinet should meet to ensure efficient
cooling of the converter module. An extra fan is used. The pressure drop over the
cabinet is the counterpressure the extra fan must overcome. The given fan types
and filter materials are examples. Corresponding products by another manufacturer
may be used as well. See the manufacturer’s Internet site for the detailed
specification.
Frame Temp. rise Pressure drop Extra fan type Air inlet and outlet filter by Luftfilter
Size Over module Over cabinet Min. inlet (door) Min. outlet (roof)
°C Pa mm mm
R7 30 250* RB2C-225/088 K093 or airComp 300-50 airTex G150
R2E225-AU64 by ebm 288×292 + 688×521 398×312 (2 pcs)
R8 30 250* RH35M-4EK.2F.1R by airComp 300-50 airTex G150
Ziehl-Abegg or RB4T- 288×292 + 688×521 398×312 (2 pcs)
355/170 by ebm
00096931

* inlet filter 50 % unclean

Planning the cabinet installation

 29

Preventing the recirculation of hot air

Converter cubicle from side Converter cubicle from above
A-A

Vertical air baffle

Air flow out

A A
Converter
module

Horizontal air baffle

Converter
module

Air flow in max. 40°C (104 °F)

Outside the cabinet

Prevent hot air circulation outside the cabinet by leading the outcoming hot air away
from the area where the inlet air to the cabinet is taken. Possible solutions are listed
below:
• gratings that guide air flow at the air inlet and outlet
• air inlet and outlet at different sides of the cabinet
• cool air inlet in the lower part of the front door, and an extra exhaust fan on the
roof of the cabinet.
Inside the cabinet
Prevent hot air circulation inside the cabinet with e.g. leak-proof air baffles at the
positions shown in the diagrams in section Required free space around the drive
module for cooling. No gaskets are usually required.

Cubicle heaters
Use a cubicle heater if there is a risk of condensation in the cabinet. Although the
primary function of the heater is to keep the air dry, it may also be required for
heating at low temperatures. When placing the heater, follow the instructions
provided by its manufacturer.

Planning the cabinet installation

30

Required free space around the drive module for cooling

Free space at the top of the drive module

Required free space at the top of the module for frame sizes R7 and R8 is shown
below (views of frame size R7). Note: Air inlet gratings only at the lower part of the
cabinet door are not recommended without an extra fan. The air baffles are
examples.

Air outlet on the cabinet roof and Air outlet and high air inlet gratings in
high air inlet gratings in the cabinet the cabinet door
door
200 mm
(7.87 in.)
300 mm
(11.81 in.)

Air baffles

not required if the

drive module
touches the
cabinet door

Bookshelf Flat Bookshelf Flat

See also pages 31 and 32.

Air outlet on the cabinet roof and low Air outlet and low air inlet gratings in the
air inlet gratings in the cabinet door cabinet door

300 mm
200 mm (11.81 in.)
(7.87 in.)

Air baffles

Bookshelf Bookshelf

See also pages 31 and 32.

Planning the cabinet installation

 31

Free space around units with busbars on the long side (bookshelf mounting
+H354)
The figure below shows the required free space in a unit with motor and brake
busbars connected to the left-hand side and DC busbars to the right-hand side of the
module (+H354+H356+H362+H363). The required free space when no vertical
busbars are used is also shown.

100 mm (3.94 in.) At the back no extra space is needed.

Cables connected to the output

busbars of the pedestal require
100 mm (3.94 in.) free space
around the busbars for cooling.

100 mm (3.94 in.)

50 mm (1.97 in.)

50 mm (1.97 in.)
Air inlet side
Cables connected
to the vertical
0 mm (0 in.)

output busbar
terminals require
150 mm (5.91 in.)

50 mm (1.97 in.)
free space around
the busbar
terminals for
cooling.

The required free space in front of the unit depends on the gratings in the cabinet
door:
• 0 mm (0 in.) with air inlets as high as the grating in the module [R7: 675 mm
(27 in.), R8: 1120 mm (44 in.)]
• 150 mm (5.91 in.) with air inlets at the lower part of the cabinet only.

Planning the cabinet installation

32

Free space around units with busbars on the short side (flat mounting +H360)
The required free space at the
air inlet side of the drive
module:
• 0 mm (0 in.) if cabinet
gratings are located at the air
inlet side of the drive module Cables connected to the vertical
and are as high as the grating output busbar terminals require
in the module [R7: 675 mm 50 mm (1.97 in.) free space around
(27 in.), R8: 1120 mm the busbar terminals for cooling.
(44 in.)]
• 150 mm (5.91 in.) with air 0 mm (0 in.) 50 mm (1.97 in.)
inlets at the lower part of the
cabinet only or with cabinet
gratings at the long side of
the drive module only.

Air inlet side of the

drive module

100 mm (3.94 in.)

Cables connected to the output busbars of the

pedestal require 100 mm (3.94 in.) free space
around the busbars for cooling.

Location of air inlet gratings

Air inlet gratings in the cabinet are recommended at the air

inlet side of the drive module if free space in front of the
long side of the module is less than 150 mm (5.91 in.). The
required area of the gratings is approximately
3 × 300 mm × 300 mm (3 × 11.81 in. × 11.81 in.), the If < 150 mm
minimum area is given on page 28. (5.91 in.)
Door
Air baffle. Not needed if the drive module touches the
cabinet door or the module air inlet touches the air inlet
grating of the cabinet.

If > 150 mm
(5.91 in.)

Required area of air inlet gratings is approximately

3 × 300 mm × 300 mm (3 × 11.81 in. × 11.81 in.)

Planning the cabinet installation

 33

When the drive module is installed in another position than vertically

• Fasten the drive module by the fastening points.
• Lay support brackets below the module to carry the module weight.
• Ensure that hot air flows freely out of the cabinet and does not build up pressure.
• Reserve enough space for the cabling.
• In case of a short-circuit inside the drive module, hot ionized gases may escape
sideways/upwards from the module through its ventilation holes. Ensure that the
cabinet is constructed so that this will not cause any danger.
• The outlet cooling air is 25...30 °C (77...86 °F) hotter than the inlet air and flows
sideways. Ensure that this does not cause danger.
• Ensure that the front panel, and preferably also the profiled side panel, can be
removed and the cooling fan and capacitor pack changed.
• Ensure that the module can be changed, e.g. by sliding out of the cabinet on rails.

Drive module of frame size R7 on its side

Note: Air inlet into the drive module

Prevent dripping water from goes through the front gratings of
Air baffle for entering the drive module. the module. Do not cover them.
preventing cooling
air recirculation Leave space in front of the
module for maintenance.

Ensure that the cooling

air will flow freely and is
clean. Use filter mats if
the input cooling air is
taken near the floor
surface and contains
dust.
Support the module from below.
The fastening points are not
sturdy enough to carry the Place the support brackets on
weight of the module when laid the same level as the spacers of
WARNING! Do not place the on its side. the back plate of the bottom exit
support brackets under the studs. kit.
They cannot carry the weight of
the drive module and the drive
module would deform when
placed onto them. The studs can
be sawn off.

64796003_bottom_exit_copy<64796003>.asm

Planning the cabinet installation

34

Drive module of frame size R7 on its back

Prevent dripping water from

entering the drive module. Note: Air inlet into the drive module
goes through the front gratings of
the module. Do not cover them.

Ensure that the cooling air will flow freely and

is clean. Use filter mats if the input cooling air Leave space above the module
is taken near the floor surface and contains for maintenance
dust.

Air baffle for preventing cooling

air recirculation

Support the module from below.

The fastening points are not
sturdy enough to carry the
weight of the module when laid
on its back.

64796003_bottom_exit_copy<64796003>.asm

Planning the cabinet installation

 35

EMC requirements
Generally, the fewer and smaller the holes in the cabinet, the better the interference
attenuation. The maximum recommended diameter of a hole in galvanic metal
contact in the covering cabinet structure is 100 mm. Special attention must be paid
to the cooling air inlet and outlet gratings.
The best galvanic connection between the steel panels is achieved by welding them
together as no holes are necessary. If welding is not possible, the seams between
the panels are recommended to be left unpainted and equipped with special
conductive EMC strips to provide adequate galvanic connection. Usually, reliable
strips are made of flexible silicon mass covered with a metal mesh. The non-
tightened touch-contact of the metal surfaces is not sufficient, so a conductive
gasket between the surfaces is required. The maximum recommended distance
between assembly screws is 100 mm.
Sufficient high-frequency grounding network must be constructed in the cabinet to
avoid voltage differences and forming of high-impedance radiator structures. A good
high-frequency grounding is made with short flat copper braids for low inductance.
One-point high-frequency grounding cannot be used due to the long distances inside
the cabinet.
First environment EMC compliance *) of the drive requires 360° high frequency
grounding of the motor cable shields at their entries. The grounding can be
implemented by a knitted wire mesh screening as shown below.

Bare cable shield

Cable ties

Knitted wire mesh

Lead-through plate

Cable

Cabinet bottom plate

*) First environment EMC compliance is defined in chapter Technical data / CE marking in ACS800-04/
04M/U4 Hardware Manual [64671006 (English)].

Planning the cabinet installation

36

360° high frequency grounding of the control cable shields is recommended at their
entries. The shields can be grounded by means of conductive shielding cushions
pressed against the cable shield from both directions:

Bare cable shield Shielding cushion

(conductive)

Cabinet bottom plate

Cable
Cable grommet

Grounding of cable shields

To power terminals Example cable lead-through

Cable shield Strain relief

PE terminal of the
cabinet or drive module

EMC sleeve *

Strip this part of

the cable

Recommended for
control cables
Base plate

Lead-through plate

* required for motor cables in first environment installations. First environment EMC compliance is
defined in chapter Technical data / CE marking in ACS800-04/04M/U4 Hardware Manual [64671006
(English)].

Installing the Drive Control Unit (RDCU)

See RDCU Drive Control Unit Hardware Manual [3AFE64636324 (English)].

Planning the cabinet installation

 37

Fastening of the control panel (CDP312R)

The control panel can be fastened directly to the cabinet door, or a mounting
platform or control panel holder (+J413) can be used.

Installing the control panel directly on the cabinet door

Fasten the control panel from the back side with two screws of one of the following
types:
• standard screw with nominal diameter of 4 mm (0.16 in.)
• tapping screw with nominal diameter of 4.2 mm (0.17 in.) DIN 7981 C,
DIN 7982 C, DIN 7983 C or DIN 7976 C
• PT screw for thermoplastics with nominal diameter of 4 mm (0.16 in.).

View from outside the cabinet door

Control panel

Cabinet door

4...8 mm
(0.16...0.31 in.)

Control panel footprint

Tightening torque:
1 Nm (0.74 lbf ft) 10 mm (0.39 in.)

Control Panel Mounting Platform RPMP-11/13 (+J410)

For installation of the mounting platform, see RPMP-11/13 Control Panel Mounting
Platform Kit Installation Guide [3AFE68400643 (English)].

Planning the cabinet installation

38

Control Panel Holder RPMP-21 (+J413)

Fasten the control panel holder to the cabinet frame or wall with three screws. Do not
fasten the panel holder to the drive module.

Planning the cabinet installation

 39

Mechanical installation of pre-assembled units

(ACS800-04/U4)

What this chapter contains

This chapter describes how to install a pre-assembled drive module into a cabinet.
First, before-installation information is given, such as required tools, moving the unit
and checking the delivery. Then, the mechanical installation procedure is described.

Moving and unpacking the unit

WARNING! The drive is heavy [frame size R7: 100 kg (220 lb), frame size R8:
200 kg (441 lb)]. Lift the drive by the upper part only using the lifting lugs attached to
the top of the unit. The lower part will be deformed from lifting. Do not remove the
pedestal before lifting.
Do not tilt the drive. The centre of gravity of the unit is high. The unit will overturn
from a tilt of about 6 degrees. An overturning unit can cause physical injury.
30°
M ax

Views of frame size R7 Do not lift by the lower Do not tilt!

part of the frame.

Mechanical installation of pre-assembled units (ACS800-04/U4)

40

Move the transport package by pallet truck to the installation site. Unpack the
package as shown below.

Undo the
fastening
screws.

The following items are located below the drive

module: The following items are fastened to
Drive Control Unit (RDCU) the drive module:
Note: Optional modules (if ordered) are • pedestal
factory installed onto the RMIO board in • output busbars U2, V2 and W2
the RDCU unit. The fibre optic cables and
• busbars for brake resistor
power supply cable to be connected to the
RMIO board are coiled on the top of the connection if brake chopper is
drive module. included.
• DC busbars if ordered

Base and wall fastening brackets,

terminals for output cable connection
and PE grounding. Screws are included Control panel with a 3 m (98 in.) cable
in a plastic bag. and RPMP control panel mounting kit (if
ordered)

Manuals (hardware, appropriate firmware,

optional module), delivery documents,
residual voltage warning stickers

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.

Mechanical installation of pre-assembled units (ACS800-04/U4)

 41

Required tools
• set of screw drivers
• torque wrench with a 500 mm (20 in.) or 2 × 250 mm (2 × 10 in.) long extension
bar
• 19 mm (3/4 in.) socket
for frame size R7: 13 mm (1/2 in.) magnetic-end socket
for frame size R8: 17 mm (11/16 in.) magnetic-end socket.

Mechanical installation of pre-assembled units (ACS800-04/U4)

42

Installation procedure

Fasten the module to the cabinet

Fasten the module to the base of the cabinet with the outside fastening brackets as
described below. For instructions in alternative fastening methods, refer to
Mechanical installation of non-pre-assembled units (ACS800-04M).
It is recommended to fasten the module also from the fastening points at the top of
the unit. Refer to Dimensional drawings for the horizontal and vertical fastening
points.
Clamping the pedestal with the outside brackets
1. Fasten the front bracket to the pedestal with two screws.
2. Fasten the back fastening bracket onto the cabinet floor with two screws.
3. Place the pedestal on the cabinet floor and push it so that the tabs of the
fastening bracket enter the slots in the pedestal.
4. Fasten the front bracket to the base with two screws.

2 2

1
M8

M8 (5/16 in.)

4 4
Tightening torque: 5 Nm (3.7 lbf ft)

Note: Place the module on a solid base. The fastening brackets are not strong
enough to carry the weight of the module on their own.

Fasten the terminals to the busbars

1. Connect the PE terminal to the long side plate of the pedestal with screws.
2. Connect the output cable terminals to the busbars with screws.
Note 1: The output cable terminals and PE terminal need not necessarily be used.
The output cables can be also connected directly to the vertical output busbar holes
with cable lugs. The PE conductors can be connected to the PE terminal screws.
Busbars for output cables can be connected to the pedestal busbars.

Mechanical installation of pre-assembled units (ACS800-04/U4)

 43

View of output busbar connections of frame size R7 (DC and brake busbars included)

Top view of insulating support and cable

lug terminal connections

Insulating support

M8x16
M8x20 M10x25

Cable lug
terminal

WARNING! The output busbars are fastened to the insulating supports with M8x16 screws
when no cable lug terminal is connected, but with M8x20 screws when a cable lug terminal
is also connected with the same screw. Screwing an M8x20 screw without a cable lug
terminal through the busbar into the insulating support will break the insulating support.
Fasten the cable lug terminals elsewhere with M10x25 screws.

2 2

2 2 Tightening torques
M8: 15...22 Nm (3.7 lbf ft)
2 2 M10: 30...44 Nm (22...32 lbf ft)

2 2

2 Spring washer with

Nut
mechanically sprayed zinc
R-

coating

Plain washer with

electroplated zinc coating
and yellow chromate
M10x30 passivation

Tightened at the factory

M8
1

Mechanical installation of pre-assembled units (ACS800-04/U4)

44

View of output busbar connections of frame size R8 (DC and brake busbars included)

WARNING! Fasten the output busbars to the insulating supports with M10x20
screws when no cable lug terminal is connected, but with M10x25 screws when a
cable lug terminal is connected as well. Screwing an M10x25 screw without a
cable lug terminal through the busbar into the insulating support will break the
insulating support.

M10x25
M10x25 M10x20

2
2
2 2 2 2
2 2 2 2
2
2

R+
W2 V2 U2 R- UDC+
UDC-

M10
2 pcs Nut Spring washer with
mechanically sprayed zinc
1
coating

Plain washer with

electroplated zinc coating
and passivation
Tightening torque M12x35
M10: 30...44 Nm (22...32 lbf ft)
Tightened at the factory
M12: 50...75 Nm (37...55 lbf ft)

User connections of Prevention of Unexpected Start (+Q950)

See pages 72 and 97.

Mechanical installation of pre-assembled units (ACS800-04/U4)

 45

Mechanical installation of non-pre-assembled units

(ACS800-04M)

What this chapter contains

This chapter describes how to assemble the drive from the assembly kits. First,
before-installation information is given, such as required tools, moving the unit and
checking the delivery. Then, the working order of the mechanical installation is
described. Thereafter, particular assembling instructions follow.

How to read this chapter

Units with bottom exit

1. Read sections Required tools and tightening torques and Moving and unpacking
the unit.
2. Go to section Frame size R7 units with bottom exit (+H352) on page 49.

Units with pedestal and busbars on the long side (+H354, bookshelf mounting)
1. Read sections Required tools and tightening torques and Moving and unpacking
the unit.
2. Identify your unit by its type code with the help of section Units with pedestal and
busbars on the long side (+H354, bookshelf mounting) on page 57.
3. Choose the applying instructions in section Assembling procedure for units with
busbars on the long side (+H354) on page 73.

Units with pedestal and busbars on the short side (+H360, flat mounting)
1. Read sections Required tools and tightening torques and Moving and unpacking
the unit.
2. Identify your unit by its type code with the help of section Units with pedestal and
busbars on the short side (+H360, flat mounting) on page 91.
3. Choose the applying instructions in section Assembling procedure for units with
busbars on the short side (+H360) on page 104.

Mechanical installation of non-pre-assembled units (ACS800-04M)

46

Required tools and tightening torques

• set of screw drivers
• torque wrench with a 500 mm (20 in.) or 2 x 250 mm (2 x 10 in.) long extension
bar
• 19 mm (3/4 in.) socket
for frame size R7: 13 mm (1/2 in.) magnetic-end socket
for frame size R8: 17 mm (11/16 in.) magnetic-end socket.
Screw Grade Tool Tightening torque
mm in. Nm lbf ft
M4 8.8 7 2 1.46
M5 8.8 8 4
M6 8.8 10 6...9 3.7
M8 8.8 13 5/16 15...22 3.7
M10 8.8 17 3/8 30...44 22...32
M12 8.8 19 1/2 50...75 37...55

Moving and unpacking the unit

WARNING! The drive is heavy [frame size R7: 100 kg (220 lb), frame size R8:
200 kg (441 lb)]. Lift the drive using the lifting lugs attached to the top of the unit. Do
not tilt the drive. The centre of gravity of the unit is high. The unit will overturn
from a tilt of about 6 degrees. An overturning unit can cause physical injury.
0°3
Max

Do not tilt!

Mechanical installation of non-pre-assembled units (ACS800-04M)

 47

The module is delivered in a two-level package. Unpack the package as shown

below.

Move the transport package by pallet truck to the installation site. Lift up the
top cover. The following items are located in the upper package (1):
• pedestal
• output busbars U2, V2 and W2
• supports, screws and terminals for the output busbars and PE grounding
• fastening brackets for base and wall mounting
• busbars for brake resistor connection (if brake chopper is ordered)
• adapter (if output busbars on the short side of the module)
1
• DC busbars (if ordered)
• control panel and a 3 m (98 in.) cable (if ordered)
• control panel mounting platform (if ordered).

In the lower package (2):

• drive module.
Below the drive module (3):
• Drive Control Unit (RDCU). Note: The fibre optic cables and power supply
cable to be connected to the RMIO board inside the RDCU unit are wound
on the top of the drive module.
• optional modules (if ordered) factory installed onto the RMIO board in the
RDCU unit
• residual voltage warning and output busbar stickers
2
• hardware manual
• appropriate firmware manuals and guides
• delivery documents
• optional module manuals.

Top view

Bottom view

Undo the fastening

3
screws.

Mechanical installation of non-pre-assembled units (ACS800-04M)

48

Fasten the lifting hooks to the lifting

lugs of the drive module. A hook can
be fastened to the base bracket also.
Use at least three fastening points
because the module is turns over
easily.

Mechanical installation of non-pre-assembled units (ACS800-04M)

 49

Frame size R7 units with bottom exit (+H352)

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.
ACS800-04M of frame size R7 with bottom exit
Package Parts Assembling drawing / reference to instruction
ProE code 64770306 D

Basic unit (type code ACS800-0M4-xxxx-x+H352)

Refer to section Assembling procedure on page 53.

Drive module

Front
-

See RDCU Drive Control Unit Hardware Manual

[3AFE64636324 (English)].
Drive control unit

RDCU drive control unit

(RDCU)

Mechanical installation of non-pre-assembled units (ACS800-04M)

50

ACS800-04M of frame size R7 with bottom exit

Package Parts Assembling drawing / reference to instruction
ProE code 64770306 D

68324963

Front

L-plate

Spacers for wall mounting

Bottom exit kit R7
+H352

R-busbar with
fastening pin

Bottom plate

Mechanical installation of non-pre-assembled units (ACS800-04M)

 51

ACS800-04M of frame size R7 with bottom exit

Package Parts Assembling drawing / reference to instruction
ProE code 64770306 D

Optional selection +H352+B060: top entry busbar shroud and bottom exit shroud
68363977
Top entry busbar shroud kit R7
+B060

68339545
Bottom exit shroud kit R7
+B060

Screws

Mechanical installation of non-pre-assembled units (ACS800-04M)

52

ACS800-04M of frame size R7 with bottom exit

Package Parts Assembling drawing / reference to instruction
ProE code 64770306 D

Example assembly+H352+B060: bottom exit with top entry busbar shroud and bottom exit shroud

Top entry busbar shroud

kit (+B060)

Front

Bottom exit
kit (+H352)

Bottom exit shroud kit

(+B060)

Mechanical installation of non-pre-assembled units (ACS800-04M)

 53

Assembling procedure
Assemble the units with bottom exit (+H352) as follows:
1. Remove the front cover of the drive module.
2. Fasten the L-plate to the base of the module.
A. Insert the two pins of the longer side of the L-plate to the counter holes in the side plate of the
drive module.
B. Slide the L-plate horizontally to match the three pins in its shorter side with the counter holes in
the drive module.
C. Fasten the L-plate with 5 screws.

B
C
C C
C
C

Mechanical installation of non-pre-assembled units (ACS800-04M)

54

3. Fasten the bottom plate to the base of the drive module.

A. With brake chopper option (+D150), fasten R- busbar to the
bottom plate with pin A1.
B. Insert the bottom plate onto its place.
C. Connect the busbars of the bottom plate to the busbars of the
drive module with M8x25 combi screws using a torque wrench
with an extension bar. Tightening torque: 15...22 Nm
(11...16 lbf ft).
D. Fasten the bottom plate to the drive module with four M6
screws. Tightening torque: 6...9 Nm (3.7 lbf ft).

A A1

C
C
C D
C
R+/UDC+
C

UDC- U2 V2

W2

C R- D
D

4. Fasten the front cover.

Mechanical installation of non-pre-assembled units (ACS800-04M)

 55

Fastening the spacer

Fasten the the drive module to the cabinet or wall using a spacer at the top of the
module on the fastening side.

Fastening the spacer to the long side of the module Fastening the spacer to the short side of the module
(flat mounting) (bookshelf mounting)

Fastening the top entry busbar and bottom exit shrouds (+B060)
Top entry busbar shroud

5 Fasten the shroud to the drive module

5

5 Remove the
2 protective film.
Press the top cover on the 3
sides inwards to enable its tabs 1 Step drill lead-throughs
to enter the slots in the shroud 3 for the busbars.
when it is placed in position (4).

Mechanical installation of non-pre-assembled units (ACS800-04M)

56

Bottom exit shroud

Fasten the side plates to the

4
drive module.

Remove the protective film from all parts.

2

3 Fasten the L-plate to

the drive module.

1 Step drill lead-

5 throughs for the
busbars.
Fasten the bottom to
the shroud

Mechanical installation of non-pre-assembled units (ACS800-04M)

 57

Units with pedestal and busbars on the long side (+H354, bookshelf
mounting)

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.

Item packages
The following tables show what each item package contains:
• parts
• part list code
• plus code
• assembling instruction.
In the tables, the basic unit is described first, then the possible optional parts are
listed. Choose the table and options of your delivery in the following sections:
• Item packages of frame size R7 with busbars on the long side on page 58.
• Item packages of frame size R8 with busbars on the long side on page 64.
Note: The complete assembling instructions are represented under Assembling
procedure for units with busbars on the long side (+H354) on page 73.

Mechanical installation of non-pre-assembled units (ACS800-04M)

58

Item packages of frame size R7 with busbars on the long side

ACS800-04M of frame size R7 with busbars on the long side
Package Parts Assembling drawing / reference to instruction
ProE code 64770306 D

Basic unit (type code ACS800-0M4-xxxx-x+H354+H355)

Refer to section Assembling procedure for units with
busbars on the long side (+H354) on page 73.

Drive module

Front
-

See RDCU Drive Control Unit Hardware Manual

[3AFE64636324 (English)].
Drive control unit

RDCU drive control unit

(RDCU)

Mechanical installation of non-pre-assembled units (ACS800-04M)

 59

ACS800-04M of frame size R7 with busbars on the long side

Package Parts Assembling drawing / reference to instruction
ProE code 64770306 D

64754416 Base mounting from outside:

Pedestal R7

Pedestal
+H354

64743309

PE terminals
right
Mounting bracket and grounding terminal kit R7

left
Front

Wall mounting:
Base mounting brackets
+H354

Wall mounting bracket

Spacer for wall mounting

Front

Mechanical installation of non-pre-assembled units (ACS800-04M)

60

ACS800-04M of frame size R7 with busbars on the long side

Package Parts Assembling drawing / reference to instruction
ProE code 64770306 D

64743180

Motor cable terminals

Insulating
Motor output busbar kit R7

supports

Support brackets
+H355

AC output busbars

Front

Optional selection +J413: Control Panel Holder RPMP-21

68394961
Control panel holder
+J413

Control panel holder

Mechanical installation of non-pre-assembled units (ACS800-04M)

 61

ACS800-04M of frame size R7 with busbars on the long side

Package Parts Assembling drawing / reference to instruction
ProE code 64770306 D

Optional selection +H354+H356+H362: DC/brake busbars

64769341
Front
Pedestal DC busbar kit R7

Pedestal busbars
+H356

64744747
DC output busbar kit R7

Insulating
supports
+H362

Terminals

Side busbars

Front

Mechanical installation of non-pre-assembled units (ACS800-04M)

62

ACS800-04M of frame size R7 with busbars on the long side

Package Parts Assembling drawing / reference to instruction
ProE code 64770306 D

Optional selection +H354+H356+H362+H363: DC and brake busbars on opposite sides

64744895 DC busbars on the right side:
Bilateral DC output busbar kit R7

Long DC busbar for the

pedestal (ends on both Front
sides of the pedestal)
+H363

DC busbars on the left side and brake busbars on

the right side:

Front

Mechanical installation of non-pre-assembled units (ACS800-04M)

 63

ACS800-04M of frame size R7 with busbars on the long side

Package Parts Assembling drawing / reference to instruction
ProE code 64770306 D

Example assembly (+H354+H355+H356+H362+H363 included)

AC, brake and

DC busbars on
the left Front
+H355

+H363

AC and brake busbars on the left and

DC busbars on the right

+H362

+H354
+H356

Mechanical installation of non-pre-assembled units (ACS800-04M)

64

Item packages of frame size R8 with busbars on the long side

ACS800-04M of frame size R8 with busbars on the long side
Package Parts Assembling instruction ProE code 64772023 E
Basic unit (type code ACS800-04M-xxxx-x+H354+H355)
Refer to section Assembling procedure for units with
busbars on the long side (+H354) on page 73.

Drive module
Front
-

See RDCU Drive Control Unit Hardware Manual

[3AFE64636324 (English)].
Drive control unit

RDCU drive control unit

(RDCU)

Mechanical installation of non-pre-assembled units (ACS800-04M)

 65

ACS800-04M of frame size R8 with busbars on the long side

Package Parts Assembling instruction ProE code 64772023 E
64754424 Base mounting from outside:

Pedestal
Pedestal R8
+H354

64744330
Front
left right Wall mounting:
PE terminals
Mounting bracket and grounding
terminal kit R8 (+H354)

Wall mounting bracket

Base mounting
brackets

Front

64743295

Motor cable terminals

Insulating
supports
Motor output busbar kit R8
+H355

Support brackets

AC output busbars
Front

Mechanical installation of non-pre-assembled units (ACS800-04M)

66

ACS800-04M of frame size R8 with busbars on the long side

Package Parts Assembling instruction ProE code 64772023 E
Optional selection +H354+H356+H362: DC/brake busbars
64769359

Insulating supports and connecting busbars

Pedestal DC busbars
Pedestal DC busbar kit R8

Front
H356

Pedestal when
DC busbars
installed

Front

64744755
Insulating supports
DC output busbar kit R8

Terminals
Side busbars
H362

Front

Mechanical installation of non-pre-assembled units (ACS800-04M)

 67

ACS800-04M of frame size R8 with busbars on the long side

Package Parts Assembling instruction ProE code 64772023 E
Optional selection +H354+H356+H363: DC and brake busbars on opposite sides
64744798 DC output on the right side:
Support brackets

Terminal

Output busbar
Insulating support

Long DC busbar for the pedestal Front

DC output on the right

Bilateral DC output busbar kit R8
+H363

Brake output on the

right and DC output on
the left

Mechanical installation of non-pre-assembled units (ACS800-04M)

68

ACS800-04M of frame size R8 with busbars on the long side

Package Parts Assembling instruction ProE code 64772023 E
Optional selection +J413: Control Panel Holder RPMP-21
68394961
Control panel holder
+J413

Control panel holder

Mechanical installation of non-pre-assembled units (ACS800-04M)

 69

ACS800-04M of frame size R8 with busbars on the long side

Package Parts Assembling instruction ProE code 64772023 E
Example assembly (+H354+H355+H356+H362+H363 included): AC and brake or DC busbars on the left, brake or
DC busbars on the right

View when vertical busbars are not

connected

View with vertical busbars connected

Note: All possible installation positions are shown. Actually DC
and brake busbars can only be located on one side each.

Front

+H355

+H362
+H363
+H356
+H354

Mechanical installation of non-pre-assembled units (ACS800-04M)

70

ACS800-04M of frame size R8 with busbars on the long side

Package Parts Assembling instruction ProE code 64772023 E
Optional selection +B060: shrouds for vertical busbars and input terminals
68341493
Top entry busbar shroud kit

Top entry busbar shroud

+B060

Fastening screws included

Mechanical installation of non-pre-assembled units (ACS800-04M)

 71

ACS800-04M of frame size R8 with busbars on the long side

Package Parts Assembling instruction ProE code 64772023 E
68329639

Vertical busbar shrouds

Vertical busbar shroud kit
+B060

Alternative
positions
Fastening screws included

Mechanical installation of non-pre-assembled units (ACS800-04M)

72

ACS800-04M of frame size R8 with busbars on the long side

Package Parts Assembling instruction ProE code 64772023 E
Example assembly (+H354+H355+H356+H362+B060+Q950 included): top entry busbar shroud, vertical busbar
shroud and Prevention of Unexpected Start

+B060

600 mm (23.62 in.)

1 = GND
2 = N
3 = L
Front
Terminal block for user
connection of Prevention of
Unexpected Start (+Q950 ).
The other end of the cable is
connected to AGPS board
terminal X1. The terminal
block can be fastened to the
cabinet frame or wall with
screws.
+B060

Note: The protective

films on the shrouds
must be removed
before installing.

+Q950 Prevention of
Unexpected Start.
Location of AGPS
board.

Mechanical installation of non-pre-assembled units (ACS800-04M)

 73

Assembling procedure for units with busbars on the long side (+H354)

Working order
References to instructions in this chapter are printed in italic in the table below. The
pictures represent frame size R7 with the following orientations.

Front

Pedestal viewed from above

Left Right

Step If Instruction

1 W2
AC busbars on
the left side
Go to step 2.

Preparing V2
U2
the pedestal

AC busbars on 1. See Swapping the busbars of the pedestal to the other side on
W2 the right side page 78.
V2 2. Go to step 2.
U2

AC busbars, R-, 1. See Connecting the DC busbars to the pedestal (+H356 and
W2 R+/UDC+ and +H363 only) on page 76.
V2 UDC- busbars on 2. Go to step 2.
U2 the left side
R- (+H356 required)
UDC+/R+
UDC-

AC busbars, R-, 1. See Swapping the busbars of the pedestal to the other side on
W2 R+/UDC+ and page 78.
V2 UDC- busbars on 2. See Connecting the DC busbars to the pedestal (+H356 and
U2 the right side +H363 only) on page 76.
R- (+H356 required) 3. Go to step 2.
UDC+/R+
UDC-

AC busbars and 1. See Swapping the busbars of the pedestal to the other side on
W2 R-, R+/UDC+ page 78 and Optional selection +H363 on page 79.
V2 busbars on the 2. See Connecting the DC busbars to the pedestal (+H356 and
U2 left side and +H363 only) on page 76.
R- UDC+ and UDC-
3. Go to step 2.
UDC+/R+ busbars on the
UDC- right side
(+H356 and
+H363 required)

Mechanical installation of non-pre-assembled units (ACS800-04M)

74

Step If Instruction
AC busbars and 1. See Swapping the busbars of the pedestal to the other side on
W2 UDC+ and UDC- page 78 and Optional selection +H363 on page 79.
V2 busbars on the 2. See Connecting the DC busbars to the pedestal (+H356 and
U2 left side and R-, +H363 only) on page 76.
R- R+/UDC+
3. Go to step 2.
UDC+/R+ busbars on the
UDC- right side
(+H356 and
+H363 required)

2 Base mounting
from outside
1. See Clamping the pedestal with the outside brackets on page
80.
W2 2. Go to step 3.
Fastening V2
the pedestal U2
by the base
(not performed
for wall-
mounted units)
Base mounting 1. See Fastening the pedestal through the holes inside the
W2 from inside pedestal on page 80.
V2 2. Go to step 3.
U2

3 Units with vertical 1. See Fastening the output busbars and PE terminal and sliding
busbars the module in on page 86.
Fastening 2. See Fastening the drive module to the pedestal on page 89.
the busbars 3. Go to step 4.
and module
to the
pedestal

Units with no 1. See Fastening the drive module to the pedestal on page 89.
vertical busbars 2. Go to step 4 (wall-mounted units) or 5 (base-mounted units).

4 wall-mounted unit See Fastening the drive module to wall (wall-mounted units only,
not for base-mounted units) on page 81.
Wall
mounting

Mechanical installation of non-pre-assembled units (ACS800-04M)

 75

Step If Instruction

5 base-mounted
unit
See Fastening the drive module by top to the cabinet frame on
page 81.
Fastening by
top

6 if included Frame size R7

See Top entry busbar shroud in section Fastening the top entry
Fastening busbar and bottom exit shrouds (+B060) on page 55.
shrouds Frame size R8
See Fastening the shrouds in frame size R8 on page 90.

Mechanical installation of non-pre-assembled units (ACS800-04M)

76

Connecting the DC busbars to the pedestal (+H356 and +H363 only)

Procedure
1. Screw insulating supports (“a” below) onto the free pins (“b” below) on the inner
sides of the pedestal.
2. Push busbars (c) through the R-, R+/UDC+ and UDC- lead-through insulators as
the W2, V2 and U2 busbars.
3. Connect the connecting busbars (d, e, f) to the insulating supports and to the R-,
R+/UDC+ and UDC busbars as shown below.
For +H363, see also Optional selection +H363 on page 79.

Photos of frame size R7

d
a
b
e a

f
R- R+ UDC-
a
UDC+

d e

DC busbars connected

PE busbar f

Mechanical installation of non-pre-assembled units (ACS800-04M)

 77

Photos of frame size R8

d
a

a e

R- R+ UDC-
UDC+

d f
a

DC busbars connected

Mechanical installation of non-pre-assembled units (ACS800-04M)

78

Busbars to the left- or right-hand side of the module?

The pedestal is delivered from the factory ready for left-hand side busbar
connections. When required, the internal busbars of the pedestal can be swapped to
the right side.
Swapping the busbars of the pedestal to the other side
When swapping the busbars from left to right, proceed as follows:
1. Turn the pedestal over to access the bolts which connect the pedestal power
connections to the horizontal busbars.
2. Undo the connections.
3. Pull out the busbars and rotate them 180 degrees.
4. Reinsert the busbars so that the busbar ends with the hole protrude on the right-
hand side of the pedestal.
5. Positions the busbars so that the small hole in the busbar is aligned with the hole
in the insulator.
6. Tighten the connections (2).
7. Connect the right-hand side PE terminal.

3
3
5
4 2
3
4 2
3
4 2

Busbar after turning around 3

4 2
New position
3 of the busbar
4 2

3
4 2

Pedestal upside down (busbar ends at

7
the left, PE terminal at the right)

Plain washer with electroplated zinc

coating and passivation
2 M10x30 (frame size R7)
M12x35 (frame size R8)

Spring washer with mechanically

sprayed zinc coating

Mechanical installation of non-pre-assembled units (ACS800-04M)

 79

Optional selection +H363

This selection enables the connection of the DC output and the brake resistor output
to the opposite sides of the pedestal. The installation below requires also optional
selection +H356. The UDC- busbar and R- busbar are taken from the +H356 parts,
the R+/UDC+ busbar from the +H363 parts. For instruction on how to connect the
busbars to the pedestal frame, see Connecting the DC busbars to the pedestal
(+H356 and +H363 only) on page 76.
1. Connect the UDC- busbar.
2. Connect the R+/UDC+ busbar.
3. Connect the R- busbar.

1 UDC-

R+ 2 UDC+

R- 3

U2

V2

W2 Pedestal upside down

DC output connected to the right

Mechanical installation of non-pre-assembled units (ACS800-04M)

80

Fastening the pedestal to the cabinet base (not for wall-mounted units)
Fasten the pedestal to the base of the cabinet either with the outside fastening
brackets or by using the fastening holes inside the pedestal.
Note: Place the module on a solid base. The fastening brackets are not strong
enough to carry the weight of the module on their own.
Clamping the pedestal with the outside brackets
1. Fasten the front bracket to the pedestal with two screws.
2. Fasten the back fastening bracket onto the cabinet floor with two screws.
3. Place the pedestal on the cabinet floor and push it so that the tabs of the
fastening bracket enter the slots in the pedestal.
4. Fasten the front bracket to the base with two screws.

2 2

1
M8

M8 (5/16 in.)

4 4
Tightening torque: 5 Nm (3.7 lbf ft)

Fastening the pedestal through the holes inside the pedestal

Fasten the pedestal to the base of the cabinet with four screws through the inside
fastening points.

M6, 5 Nm (3.7 lbf ft)

Mechanical installation of non-pre-assembled units (ACS800-04M)

 81

Fastening the drive module by top to the cabinet frame

In addition to the base fastening, it is recommended to fasten the module to the
cabinet also from the fastening points at the top. Refer to Dimensional drawings for
the vertical fastening points.
If the module is not fastened from the back top to the cabinet frame, it must be
fastened from the front top fastening points during transportation or in case of
vibration.

Fastening the drive module to wall (wall-mounted units only, not for base-mounted
units)
Requirements for protection
The drive module must be protected against contact, dust and humidity (see chapter
Technical data in ACS800-04/04M/U4 Hardware Manual [64671006 (English)].
Requirements for the wall
The wall must 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 must be non-flammable.

Mechanical installation of non-pre-assembled units (ACS800-04M)

82

Procedure
• Place the wall mounting bracket onto the pedestal so that its pins enter the slots
of the pedestal.
• Fasten the pins with nuts (1) from inside or fasten the bracket with screws from
outside (2). The nuts and screws are included in the mounting bracket package.

Inserting the wall

mounting bracket into the
slots in the pedestal

1 2

2
1

The pins of the wall mounting bracket are fastened with Fastening the wall mounting bracket with screws from
nuts from inside outside (alternative to pin fastening from inside)

Mechanical installation of non-pre-assembled units (ACS800-04M)

 83

• See Dimensional drawings for locations of the fastening points at the top of the
module.
• Use a pallet truck or a lifter to move the unit to the final mounting place.

WARNING! Secure the unit to eliminate the danger of overturning and falling
during the fastening precedure.

• Fasten the module through the slots in the wall mounting bracket and the
fastening holes at the top of the module using spacers between the module and
the wall.
Note: In flat mounting, the spacers (at the top and bottom) provide a clearance of 15 mm (0.6 in.)
between the drive module and the wall so that the protruding studs of the module will not press
against the wall. In bookshelf mounting, the spacer removes a 4 mm (0.16 in.) gap between the
drive module top and the wall so that the module will hang in an upright position.

• Fasten the module also by top front with a wall-fastened support bracket.

Mechanical installation of non-pre-assembled units (ACS800-04M)

84

Units with busbars on the short sides (flat mounting, frame sizes R7 and R8)

15 mm (0.6 in.)

View from above

Spacer viewed from front (frame size R7)

Side view
R7

View from below

Screw size: M10 for frame sizes R7 and R8

Fastening points of frame size R8

Top

Bottom

Mechanical installation of non-pre-assembled units (ACS800-04M)

 85

Units with busbars on the long side (bookshelf mounting, frame sizes R7 and R8)

4 mm (0.6 in.)

Frame size R7 with spacer

Frame size R8: no spacer

View from above

no spacer

Spacer (frame size R7)

Side view

Screw size: M10 for frame sizes R7 and R8

Fastening points of frame size R7

Top

Bottom

Mechanical installation of non-pre-assembled units (ACS800-04M)

86

Fastening the output busbars and PE terminal and sliding the module in
The steps of this installation procedure are shown in the photos on the next pages.
1. Connect the output busbars to the pedestal.
2. Fasten the PE terminal.
3. Screw the insulating supports onto the pins on the outer support bracket.
4. Fasten the output busbars and terminals to the insulating supports on the outer
support bracket.
5. Fasten the inner support bracket to the drive module.

M6x16
R7

M6x12

R8

6. Remove the fastening brackets (screws “b” on photos under Fastening the drive
module to the pedestal on page 89) from the pedestal.
7. Slide the module onto the pedestal so that the inner support bracket enters inside
the outer support bracket.
8. Fasten the outer support bracket to the drive module.
9. Fasten the stickers to the output busbars.

Mechanical installation of non-pre-assembled units (ACS800-04M)

 87

View of output busbar connections of frame size R7 (DC and brake busbars included)

Top view of insulating support and cable

lug terminal connections

Insulating support

M8x16
M8x20 M10x25

Cable lug
terminal

WARNING! Fasten the output busbars to the insulating supports with M8x16 screws when
no cable lug terminal is connected, but with M8x20 screws when a cable lug terminal is also
connected with the same screw. Screwing an M8x20 screw without a cable lug terminal
through the busbar into the insulating support will break the insulating support. Fasten the
3 cable lug terminals elsewhere with M10x25 screws.

4
8
4

Tightening torque
M8: 15...22 Nm (3.7 lbf ft)
M10: 30...44 Nm (22...32 lbf ft)

Nut Spring washer with

mechanically sprayed zinc
R-

coating
1
Plain washer with
electroplated zinc coating
and passivation
M10x30

M8
2

Mechanical installation of non-pre-assembled units (ACS800-04M)

88

View of output busbar connections of frame size R8 (DC and brake busbars included)

WARNING! Fasten the output busbars to the insulating supports with M10x20
screws when no cable lug terminal is connected, but with M10x25 screws when a
cable lug terminal is connected as well. Screwing an M10x25 screw without a
cable lug terminal through the busbar into the insulating support will break the
insulating support.

M10x25
M10x25 M10x20

4
4
4 4 4 4 8 5
3
4 4 4
4
4
4

R+
W2 V2 U2 R- UDC+
UDC-

9
M10
2 pcs Nut Spring washer with
mechanically sprayed zinc
2
coating
1
Plain washer with
electroplated zinc coating
and passivation
Tightening torque M12x35
M10: 30...44 Nm (22...32 lbf ft)
M12: 50...75 Nm (37...55 lbf ft)

Mechanical installation of non-pre-assembled units (ACS800-04M)

 89

Fastening the drive module to the pedestal

• Remove the front cover of the module.
• Connect the busbars with screws [3 to 6 pcs (a)] using a torque wrench with an
extension bar.
• Fasten the module to the pedestal with screws (b).

WARNING! Fastening of screws (b) is important because the screws are required
for the grounding of the drive.

Frame size R7
a
b a M8x25 combi screw
Tightening torque: 15...22 Nm
a a a b (11...16 lbf ft)
b
a b
b M6 combi screw
a
Tightening torque: 5 Nm (3.7 lbf ft)
Pedestal

UDC- UDC+ Frame size R8

U2 V2 W2

b b
b b
a a a a a

a M10x25 combi screws b M6x16 combi screws

Tightening torque: 30...44 Nm (22...32 lbf ft) Tightening torque: 5 Nm (3.7 lbf ft)

• Match the three guide pins on the cover with the counter holes. Fasten the front
cover to the module with screws.

Mechanical installation of non-pre-assembled units (ACS800-04M)

90

Fastening the shrouds in frame size R8

Top entry busbar shroud

4
3

4 Fasten the
shroud to the
drive module.
Place the top cover to
position (3) with the tabs
entering the slots of the
shroud. 2 Remove the protective
film.
1
Step drill lead-throughs Top entry busbar shroud fastened
for the busbars.

Vertical busbar shroud

2 Remove the protective film from the

shroud surfaces.
Alternative
positions

Used in the right-

hand-side assembly

1
Cut the corner piece
to make space for
the PE terminal of 3 Fasten the shroud plates to
the drive module. Vertical busbar shroud fastened
each other and to the drive
module.
Note: When connecting the power cables,
remove the front (and top and side) shroud by
undoing the fastening screws.

Mechanical installation of non-pre-assembled units (ACS800-04M)

 91

Units with pedestal and busbars on the short side (+H360, flat mounting)

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.

Item packages
The following tables show what each item package contains:
• parts
• part list code
• plus code
• assembling instruction.
In the tables, the basic unit is described first, then the possible optional parts are
listed. Choose the table and options of your delivery in the following sections:
• Item packages of frame size R7 with busbars on the short side on page 92.
• Item packages of frame size R8 with busbars on the short side on page 98.
Note: The complete assembling instructions are represented under Assembling
procedure for units with busbars on the short side (+H360) on page 104.

Mechanical installation of non-pre-assembled units (ACS800-04M)

92

Item packages of frame size R7 with busbars on the short side

ACS800-04M with busbars on the short side (frame size R7)
Package Parts Assembling drawing / reference to instruction
ProE code 64770306 D

Basic unit (type code ACS800-04M-xxxx-x+H355+H360)

Refer to section Assembling procedure for units with
busbars on the short side (+H360) on page 104.

Drive module

Front
-

See RDCU Drive Control Unit Hardware Manual

[3AFE64636324 (English)].
Drive control unit

RDCU drive control unit

(RDCU)

Mechanical installation of non-pre-assembled units (ACS800-04M)

 93

ACS800-04M with busbars on the short side (frame size R7)

Package Parts Assembling drawing / reference to instruction
ProE code 64770306 D

64749404

Pedestal
Base mounting if clamped
Pedestal R7 +H360

from outside

Front
Spacers for wall
mounitng

64745808
grounding terminal kit R7 +H360

PE terminals
Mounting bracket and

Base mounting
brackets

Wall mounting
Wall mounting bracket
Note: DC and brake busbars (+H356) are
included in the drawing

64749391
Front (view from above)
Adapter (viewed
from the side that
Adapter R7
+H360

will mate with the

drive module)

Mechanical installation of non-pre-assembled units (ACS800-04M)

94

ACS800-04M with busbars on the short side (frame size R7)

Package Parts Assembling drawing / reference to instruction
ProE code 64770306 D

64744402
Insulating
supports

AC support
brackets
Motor output busbar kit R7 + H355

Motor cable
terminals

AC output busbars

Front

Optional selection +J413: Control Panel Holder RPMP-21

68394961
Control panel holder
+J413

Control panel holder

Mechanical installation of non-pre-assembled units (ACS800-04M)

 95

ACS800-04M with busbars on the short side (frame size R7)

Package Parts Assembling drawing / reference to instruction
ProE code 64770306 D

Optional selection +H360+H356+H362: DC/brake busbars

64769375
Front (view from above)
Insulating supports
Adapter DC busbar kit R7
+H356 (+H360 required)

Connecting busbars

Insulating supports
Front
Pedestal DC busbar kit R7
+H356 (+H360 required)

Connecting busbars

Pedestal DC busbars

Mechanical installation of non-pre-assembled units (ACS800-04M)

96

ACS800-04M with busbars on the short side (frame size R7)

Package Parts Assembling drawing / reference to instruction
ProE code 64770306 D

64744763
Insulating
supports

DC support
brackets
+H362 (+H360 required)
DC output busbar kit R7

Terminals Side busbars

Front

Mechanical installation of non-pre-assembled units (ACS800-04M)

 97

ACS800-04M with busbars on the short side (frame size R7)

Package Parts Assembling drawing / reference to instruction
ProE code 64770306 D

Example assembly +H360+H355+H356+H362: DC and brake busbars included

500 mm (19.68 in.) 1 = GND

2 = N
3 = L
Terminal block for user connection
of Prevention of Unexpected Start
(+Q950 ). The other end of the
cable is connected to AGPS board
terminal X1. The terminal block
can be fastened to the cabinet
frame or wall with screws.

+Q950 Prevention of
Unexpected Start.
Location of AGPS
board.

+H355

Front

+H362

+H360

+H356

Mechanical installation of non-pre-assembled units (ACS800-04M)

98

Item packages of frame size R8 with busbars on the short side

ACS800-04M with busbars on the short side (frame size R8)
Package Parts Assembling drawing / reference to instruction
ProE code 64772023 E

Basic unit (type code ACS800-04M-xxxx-x+H355+H360)

Refer to section Assembling procedure for units with
busbars on the short side (+H360) on page 104.

Drive module
Front
-

See RDCU Drive Control Unit Hardware Manual

[3AFE64636324 (English)].
Drive control unit

RDCU drive control unit

(RDCU)

Mechanical installation of non-pre-assembled units (ACS800-04M)

 99

ACS800-04M with busbars on the short side (frame size R8)

Package Parts Assembling drawing / reference to instruction
ProE code 64772023 E

64749978

Pedestal
Pedestal R8 +H360

Front
Spacers for wall
mounting Front
Upper
Wall mounting
Lower

64745794

Insulating support

PE terminal

L-bracket (used when U2 output

busbar is not installed)

Base mounting
brackets
grounding terminal kit R8 +H360

Front
Wall mounting
Mounting bracket and

bracket
Base mounting if clamped from outside

Front

PE busbar if pedestal busbars are

swapped to the left. Note: vertical busbars
cannot be used.

Mechanical installation of non-pre-assembled units (ACS800-04M)

100

ACS800-04M with busbars on the short side (frame size R8)

Package Parts Assembling drawing / reference to instruction
ProE code 64772023 E

64749871

Adapter (viewed View from above

from the side that
will mate with the
drive module) Front
Adapter R8
+H360

64744453
Insulating supports
Motor output busbar kit R8 + H355

Motor cable terminals

AC support brackets

AC output busbars

Front

Optional selection +J413: Control Panel Holder RPMP-21

68394961
Control panel holder
+J413

Control panel holder

Mechanical installation of non-pre-assembled units (ACS800-04M)

 101

ACS800-04M with busbars on the short side (frame size R8)

Package Parts Assembling drawing / reference to instruction
ProE code 64772023 E

Optional selection +H356+H362+H360: DC/brake busbars

64769456

Insulating
supports View from above

Front
Adapter DC busbar kit R8
+H356 (+H360 required)

Connecting busbars

Front

Adapter when
DC busbars
installed

Mechanical installation of non-pre-assembled units (ACS800-04M)

102

ACS800-04M with busbars on the short side (frame size R8)

Package Parts Assembling drawing / reference to instruction
ProE code 64772023 E

Insulating supports
Front
Connecting busbars
Pedestal DC busbar kit R8
+H356 (+H360 required)

Front
Pedestal DC busbars

Pedestal
when DC
busbars
installed

64744771

M10x20
Insulating
Terminals
supports
M10x25
+H362 (+H360 required)
DC output busbar kit R8

Side busbars Front

M10x35

Mechanical installation of non-pre-assembled units (ACS800-04M)

 103

ACS800-04M with busbars on the short side (frame size R8)

Package Parts Assembling drawing / reference to instruction
ProE code 64772023 E

Example assembly +H355+H356+H360+H362: DC/brake busbars included

View when vertical busbars are not

connected

+H360

Front
View with vertical busbars
connected

+H362

+H356 +H360
+H355

Mechanical installation of non-pre-assembled units (ACS800-04M)

104

Assembling procedure for units with busbars on the short side (+H360)

Working order
References to instructions in this chapter are printed in italic in the table below. The
pictures represent frame size R7 with the following orientations.

Front

Pedestal viewed from above

Left Right

Step If Instruction

1 AC busbars on
W2 the right side
Go to step 2.

V2
Preparing
U2
the pedestal
AC busbars, R-, 1. See Connecting the DC busbars to the pedestal
R+/UDC+ and (+H360 +H356 only) on page 107.
UDC- busbars on 2. Go to step 2.
the right side
(+H356 required)

AC busbars on 1. See Swapping the pedestal output busbars to the

W2 the left side left-hand side on page 106.
V2 2. Go to step 2.
U2

AC busbars, R-, 1. See Swapping the pedestal output busbars to the

R+/UDC+ and left-hand side on page 106.
UDC- busbars on 2. See Connecting the DC busbars to the pedestal
the left side (+H360 +H356 only) on page 107.
(+H356 required) 3. Go to step 2.

2 AC busbars on
the right or left
Go to step 3.

side
Preparing
the adapter

AC busbars, R-, 1. See Preparing the adapter (+H360 +H356 only) on

R+/UDC+ and page 108.
UDC- busbars on 2. Go to step 3.
the right or left
side
(+H356 required)

Mechanical installation of non-pre-assembled units (ACS800-04M)

 105

Step If Instruction

3 - 1. See Fastening the adapter to the drive module on

page 109.
Fastening 2. Go to step 4.
the adapter
to the drive
module

4 Base mounting
from outside
1. See Clamping the pedestal with the outside brackets
on page 80.
Fastening 2. Go to step 5.
the pedestal
by the base
(not performed Base mounting 1. See Fastening the pedestal through the holes inside
for wall- from inside the pedestal on page 80.
mounted units) 2. Go to step 5.

5 - 1. See Fastening the drive module to the pedestal via

the adapter on page 110.
Fastening 2. Go to step 6.
the adapter
to the
pedestal

6 Units with vertical 1. See Connecting the output busbars on the short side
busbars of the module on page 111.
Connecting 2. Go to step 7.
the output
busbars

7 wall-mounted unit 1. See Fastening the drive module to wall (wall-

mounted units only, not for base-mounted units) on
Wall page 81.
mounting (not
performed for
base-mounted
units)

8 base-mounted
unit
1. See Fastening the drive module by top to the cabinet
frame on page 81.
Fastening by
top

Mechanical installation of non-pre-assembled units (ACS800-04M)

106

Swapping the pedestal output busbars to the left-hand side

• Disconnect the horizontal pedestal busbars from the busbars that connect them
to the adapter.
• Push the horizontal busbars to the left.
• Reconnect the horizontal busbars to the adapter connecting busbars.
Note:
When the pedestal busbars are swapped to the left:
• vertical output busbars cannot be installed.
• the unit cannot be mounted on a wall with the wall mounting bracket included in
the delivery.
• ensure that the required clearance between the cabinet base or floor and the
cable lugs or busbars used in the cabling is at least 13 mm (1/2 in.). Otherwise,
insulating material must be used below the drive module.
• fasten the left-hand side PE terminal in frame size R7. In frame size R8, fasten
the PE busbar as follows.

Left

Right
Front (the profiled side)

PE busbar
Fastening of the PE busbar in frame size R8

Mechanical installation of non-pre-assembled units (ACS800-04M)

 107

Connecting the DC busbars to the pedestal (+H360 +H356 only)

Required parts
Frame size R7
a a a

d f
e
b

R+
UDC+
UDC-
c
c
c
R-

Procedure
1. Screw insulating supports (“a” above) onto the free pins (“b” above) on the inner
sides of the pedestal.
2. Push busbars (c) through the R-, R+/UDC+ and UDC- lead-through insulators.
3. Connect the connecting busbars (d, e, f) to the insulating supports and to the R-,
R+/UDC+ and UDC busbars as shown below.

Frame size R7
e

f
d DC busbars connected

Frame size R8

See also chapter Assembly drawings.

Mechanical installation of non-pre-assembled units (ACS800-04M)

108

Preparing the adapter (+H360 +H356 only)

Required parts
Frame size R7 Frame size R8

a a a
b b b b
a a a
f
c
e
c
f
d
e
b
a

Procedure
1. Screw insulating supports (“a” above) onto the free pins (“b” above).
2. Connect the connecting busbars to the insulating supports as shown below.
Connect busbar c to busbar d.
Frame size R7 Frame size R8

f
f
c
e
c
e
d

See also chapter Assembly drawings.

Mechanical installation of non-pre-assembled units (ACS800-04M)

 109

Fastening the adapter to the drive module

The DC busbars (+H356) are included in the installation examples below.
1. Fasten the screws.
2. Connect the busbars.
Frame size R7 Frame size R8

1
1
1
2
1 2 2 2

2
2 1
1

2 2 2 2

1
1
2

1 1

1 1

2 Tightening torque 2 Tightening torque

M8: 15...22 Nm (3.7 lbf ft) M10: 30...44 Nm (22...32 lbf ft)

Mechanical installation of non-pre-assembled units (ACS800-04M)

110

Fastening the drive module to the pedestal via the adapter

The DC busbars (+H356) are included in the installation examples below. The
adapter has been connected to the drive module.
1. Frame size R7: Remove the “long front” side plate of the pedestal.
Frame size R8: Remove the “long front” side plate of the adapter.
2. Slide the drive module with the adapter fastened onto the pedestal.
3. Connect the busbars.
4. Frame size R7: Fasten the side plate of the pedestal.
Frame size R8: Fasten the side plate to the adapter and the pedestal.

Frame size R7 3

1 1

M6 M6

M5 M5
4 4

M5

Frame size R8

1 1 4

Mechanical installation of non-pre-assembled units (ACS800-04M)

 111

Connecting the output busbars on the short side of the module

Procedure for frame size R7
The steps of this installation procedure are shown in the photos below and on the
next page.
1. Fasten the inner support bracket (brackets if DC busbars ordered) to the drive
module with four M6 screws.
2. Screw the insulating supports onto the pins on the outer support bracket (s).
3. Slide the outer support bracket(s) on the inner bracket(s).
4. Fasten the outer support bracket(s) with two M6 screws.
5. Connect the AC busbars.
6. Connect the DC busbars (if ordered).
7. Connect the cable lug terminals. Use a M8x20 screw when the terminal is placed
on an insulating support and M10x25 screws elsewhere.
8. Connect the PE busbar.

1 5
3
M8x16
without
cable lug
1 terminal,
2
M8x20 with
4
cable lug
terminal

M10
5

Mechanical installation of non-pre-assembled units (ACS800-04M)

112

M10x25

7 M10x25
M8x16 M8x20

WARNING! Fasten the output

busbars to the insulating supports
5 with M8x16 screws when no cable
lug terminal is connected, but with
M8x20 screws when a cable lug
terminal is connected as well.
Screwing an M8x20 screw without
a cable lug terminal through the
M8x16 busbar into the insulating support
will break the insulating support.

M10x25

Tightening torque
M8: 15...22 Nm (3.7 lbf ft)
M10: 30...44 Nm (22...32 lbf ft)
M10
5

8 M8. Use the side plate fastening screw

for fastening the PE terminal by side.
PE

6 M10

Frame size R7 +H360: AC, DC and brake busbars connected (+H356 included)

Mechanical installation of non-pre-assembled units (ACS800-04M)

 113

Procedure frame size R8

The steps of this installation procedure are shown in the photo on the next page.
1. Fasten the inner support bracket to the drive module.
2. Screw the insulating supports onto the pins on the outer support bracket.
3. Slide the outer support bracket on the inner bracket.
4. Fasten the outer support bracket to the drive module.
5. Connect the AC busbars.
6. Connect the DC busbars (if ordered).
7. Connect the PE busbar.

Mechanical installation of non-pre-assembled units (ACS800-04M)

114

WARNING! Fasten the output busbars to the

insulating supports with M10x20 screws when no
cable lug terminal is connected, but with M10x25
screws when a cable lug terminal is connected as
well. Screwing an M10x25 screw without a cable lug
4 terminal through the busbar into the insulating
1
support will break the insulating support.
5

Tightening torque
M10: 30...44 Nm (22...32 lbf ft)
M12: 50...75 Nm (37...55 lbf ft)

7
PE Spring washer with
Nut
M10 mechanically sprayed zinc
coating

M10 6 Plain washer with

7 electroplated zinc coating
5
and passivation
M12x35

Frame size R8 +H360: AC, DC and brake busbars connected (+H356 included)

Mechanical installation of non-pre-assembled units (ACS800-04M)

 115

Checking the installation

What this chapter contains

This chapter contains checklists according to which the assembly of converter
modules into a cabinet is inspected at ABB factory.

Visual inspection
Inspect the mechanical and electrical installation of the converter module visually to
ensure safe testing and use of the drive.

Cabinet construction
Checks for cabinet construction are listed below.
Step Check item
1 Cabinet construction
1.1 Frame, wall, floor and roof structures, busbar enclosures and cable entries are correct and completely
assembled.
1.2 Mechanical joints are tightened and not broken.
1.3 Parts are clean and painted surfaces not scratched.
The cabinet frame and parts which are in metal to metal contact with the frame (e.g. seams,
component fixing points on assembly plates, back of control panel mounting plate) are not finished
with non-conducting paint or material.
1.4 IP enclosure class
1.5 There is a sufficient number of supports, bolts and nuts for cables.

Instrumentation, busbars and cabling

Checks for instrumentation, busbars, cabling, clearances and creepage distances
are listed below. For more information, refer to ACS800-04/04M/U4 Hardware
Manual [3AFE64671006 (English)]: Planning the electrical installation.
Step Check item
2 Instrumentation
2.1 Type and number of option modules and other equipment is correct. Option modules and other
equipment are not damaged.
2.2 Option modules and terminals are labelled correctly.
2.3 The placement of option modules and other equipment inside the cabinet and on the cabinet door is
correct.
2.4 The mounting of option modules and other equipment is correct.

Checking the installation

116

Step Check item

3 Busbars
3.1 The types (Al/Cu) and cross-sections of busbars are correct.
3.2 Busbars are intact and joint surfaces are clean. There are no metal scraps on the busbars that could
cause a short-circuit.
3.3 The placement and mounting of busbars is correct.
3.4 The electrical connection of busbars. Check that the surfaces in electrical connections of aluminium
and uncoated busbars are rubbed. Check that anti-oxidant joint compound is used in electrical
connections of aluminium busbars. Check that the number of washers and the sizes of bolts are
correct.
3.5 Busbar supports and lead-in insulators are visually intact and degreased, and placed and mounted
correctly.
3.6 The electrical connections on the main circuit are tightened to required torque and marked with a
green marking.
4 Cabling and wiring
4.1 Wiring of the main circuit. Check
• AC supply input
• AC output
• supply for brake resistor (if used).
4.2 Wiring of the 230 VAC circuit. Check
• terminal strips and relays
• supply of cabinet fans (if used)
• 24 VDC auxiliary voltage circuit (optional module supply)
• supply for cooling fan of the braking resistor(s) (if used).
4.3 Wiring of the converter module circuit. Check
• RDCU module (RMIO board) connections
• control cable connections
• control panel cable connections.
4.4 Cable types, cross-sections, colours and optional markings are correct.
4.5 Check the cabling for circuits susceptible to interference. Check the twisting of cables and cable
routes.
4.6 Check that cables without short-circuit protection
• can carry the load current
• are shorter than 3 m (10 ft)
• are assembled separate to other cables
• are protected by an enclosure or duct.
4.7 Cable connectors and fibre optic cables are intact and according to instructions. Check the termination
of cables (e.g. AMP connectors), the crimping of cable lugs and ferrules. Check that the connectors
are suitable for the cables and the correct crimping tool has been used.
Check that
• insulation of the cable is not underneath the connector
• all strands of the cable are inside the connector
• connector is not broken
• cable is deep enough in its connector.

Checking the installation

 117

Step Check item

4.8 Connection of cables to devices and terminal blocks. Check that
• cables are connected to terminals tight enough by pulling the cable
• cable termination on terminals chaining is done correctly
• bare conductors are not too far outside the terminal causing an insufficient clearance or loss of
shielding against contact.
4.9 Cables are not lying against sharp edges or bare live parts. Bending radius of fibre optic cables at least
3.5 cm (1.38 in.).
4.10 The type, markings, insulation plates and cross connections of terminal blocks are correct.
5. Clearances and creepage distances
5.1 Clearances outside the modules are at least 12.7 mm (0.5 in.).
5.2 Creepage distances outside the modules are at least 12.7 mm (0.5 in.).

Groundings and protection

Checks for groundings and protections are listed below. Tips for installations where
EMC emissions must be minimised are given in column Extra requirements for EMC.
Step Check item Extra requirements for EMC
6 Groundings and protection
6.1 The grounding colours, cross-section and grounding points No long routes for pigtails
of modules and other equipment match the circuit diagrams.
6.2 Connections of PE cables and busbars are tight enough. No long routes for pigtails
Pull the cable to test that it does not loosen.
6.3 Doors equipped with electrical equipment are grounded. No long grounding routes. From EMC standpoint
best result is achieved with a flat copper braid.
6.4 Fans that can be touched are shrouded.
6.5 Live parts inside the doors are protected against direct
contact to at least IP 2x (if required).

Checking the installation

118

Labels, switches, fuses and doors

Checks for labels, switches, fuses and doors are listed below.
Step Check item
7 Labels
7.1 The name plates are correct. The name plates are located correctly. Check the name plates for
• cabinet
• main circuit fuses
• settings of the circuit-breakers
• safety switches of the main circuit.
7.2 The warning and instruction stickers are located correctly.
Stickers required inside the cabinet:
• near all grounding connections
• inside the cabinet door main fuse specification label, fuse installation (centring) note
• on contact covers

• warning of live terminals of a blown fuse on contact cover on the main fuses
• warning about apparatus not disconnected from the supply network by the main switch on contact covers of
these busbars and apparatus
• warning sticker for residual voltages of the converter capacitor banks placed on the converter module.
Stickers required on the cabinet door:
• five-minute warning of residual voltage
•

• sticker on the control panel mounting platform (if used)

• emergency stop and start switch label (if applicable)
• main switch label.
8. Switches, fuses and doors
8.1 Check the functioning of mechanical switches by closing and opening them.
8.2 Check that fuses can be changed with a fuse handle. Check that fuse disconnectors and sockets match each
other.
8.3 Check the appropriate length and fastening of the operation rod of the main disconnecting switch.
When switch fuses or disconnecting switches are closed, the corresponding cabinet doors cannot be opened:
1. Lock the cabinet door with the main switch in OPEN position (0).
2. Close the main switch (position 1).
3. Unlock the door. It must not be possible to open the door by pulling the handle.

Checking the installation

 119

Dimensional drawings

Dimensional drawings
120

Frame size R7 without pedestal (mm)

Center of
gravity

64796003_3/7 E

Dimensional drawings
 121

Frame size R7 with bottom exit (mm)

64796003_6/7 G

Dimensional drawings
122

Frame size R7 with bottom exit and top entry and bottom exit shrouds
(mm)

64796003_7/7 E

Dimensional drawings
 123

Frame size R7 with busbars on the left side (mm)

64796003_5/7 G

Dimensional drawings
124

Frame size R7 with DC busbars on both sides (mm)

Bilateral busbar

for wall mounting only

Fastening bracket

64796003_2/7 G

Dimensional drawings
 125

Frame size R7 pedestal busbars on the long side (mm)

Bilateral output busbar

64796003_4/7 E

Dimensional drawings
126

Frame size R7 with busbars on the short side (mm)

for wall mounting only

Fastening bracket

64796003_1/7 G

Dimensional drawings
 127

Frame size R8 without pedestal (mm)

Center of
gravity

64801082_3/6 E

Dimensional drawings
128

Frame size R8 with busbars on the left side (mm)

64801082_5/6 E

Dimensional drawings
 129

Frame size R8 with top entry and vertical busbar shrouds (mm)

64801082_6/6 E

Dimensional drawings
 130

Dimensional drawings
Frame size R8 with busbars on both sides (mm)

Fastening bracket
for wall mounting only

Bilateral busbar

64801082_1/6 E
 131

Frame size R8 pedestal busbars on the long side (mm)

Bilateral output busbar

64801082_4/6 E

Dimensional drawings
 132

Spacer for wall

mounting only

Dimensional drawings
Frame size R8 with busbars on the short side (mm)

Spacer for wall

mounting only
Fastening bracket for
wall mounting only

Base fastening
bracket

Spacer for wall

mounting only
64801082_2/6 E
 133

Wall mounting spacers

Frame size R7: long side against wall

68240808 B

Frame size R7: short side against wall

A-A
A
68240166 A

Frame size R8: long side against wall

68238021 A

Dimensional drawings
134

Frame size R8: short side against wall

68377927 A

Frame size R7 bottom exit kit (+H352)

64770306_16/20 E

Dimensional drawings
 135

Frame size R7 top entry busbar shroud and bottom exit shroud (+B060)

64770306_18/20 E

64770306_17/20 E

Dimensional drawings
136

Control Panel Holder RPMP-21 (+J413)

64770306_20/20 E

Dimensional drawings
 137

Drive Control Unit (RDCU-02)

Can be mounted on a DIN rail

(EN 50022, 35 mm x 7.5 mm)

64675214-B

Dimensional drawings
138

Dimensional drawings (USA)

Dimensional drawings
 139

Frame size R7 without pedestal (inches)

Center of
gravity

68439221_3/7 A (64796003.asm E)

Dimensional drawings
140

Frame size R7 with bottom exit (inches)

F
F

68439221_6/7 F

Dimensional drawings
 141

Frame size R7 with bottom exit and top entry and bottom exit shrouds (inches)

68439221_7/7 A (64796003.asm E)

Dimensional drawings
142

Frame size R7 with busbars on the left side (inches)

68439221_5/7 F

Dimensional drawings
 143

Frame size R7 with busbars on both sides (inches)

Bilateral busbar

Fastening bracket for

wall mounting only

68439221_2/7 F

Dimensional drawings
144

Frame size R7 pedestal busbars on the long side (inches)

Bilateral output busbar

68439221_4/7 A (64796003.asm E)

Dimensional drawings
 145

Frame size R7 with busbars on the short side (inches)

for wall mounting only

Fastening bracket

68439221_1/7 F

Dimensional drawings
146

Frame size R8 without pedestal (inches)

Center of
gravity

68440513_3/6 A (64801082.asm E)

Dimensional drawings
 147

Frame size R8 with busbars on the left side (inches)

68440513_5/6 A (64801082.asm E)

Dimensional drawings
148

Frame size R8 with top entry and vertical busbar shrouds (inches)

68440513_6/6 A (64801082.asm E)

Dimensional drawings
 Frame size R8 with busbars on both sides (inches)

Fastening bracket
for wall mounting only

Bilateral busbar

68440513_1/6 A (64801082.asm E)
149

Dimensional drawings
150

Frame size R8 pedestal busbars on the long side (inches)

Bilateral output busbar

68440513_4/6 A (64801082.asm E)

Dimensional drawings
 Spacer for wall
mounting only
Frame size R8 with busbars on the short side (inches)

Spacer for wall

mounting only
Fastening bracket
for wall mounting only

Base mounting
bracket
Spacer for wall
mounting only
68440513_2/6 A (64801082.asm E)
151

Dimensional drawings
152

Dimensional drawings
 153

Circuit diagrams

What this chapter contains

This chapter shows an example circuit diagram for employing the Prevention of
Unexpected Start function (+Q950).

Circuit diagrams
 154
Components to be provided and wired by the user

Circuit diagrams
ACS800-04/04M drive module

Safety relay

00362825 B
 155

Assembly drawings

What this chapter contains

This chapter shows a few step-by-step assembly drawings.

Assembly drawings
 156
Combi screw

Basic assembly Step 1

Assembly drawings
+H356+H360)
R- busbars

Combi screw

Combi screw

Step 2
UDC- busbars

Combi screw

Combi screw

Combi screw

Step 3 Combi screw

Combi screw UDC+/R+ busbars Combi screw
Adding UDC+/R+, UDC- and R- busbars to the pedestal (frame size R7,

6844855 A
 Basic assembly
Step 1
+H356+H360)

UDC+/R+ busbar

Combi screw

Step 2
UDC- busbar Step 3
R- busbar

Combi screw

Combi screw
Adding UDC+/R+, UDC- and R- busbars to the adapter (frame size R7,

68449359 A
157

Assembly drawings
 158

Step 2

Assembly drawings
Basic assembly
R- busbar
+H356+H360)
Combi screw

Combi screw

Step 1 Step 3
UDC- busbar UDC+/R+ busbar
Combi screw
Combi screw

Combi screw

Combi screw
Adding UDC+/R+, UDC- and R- busbars to the pedestal (frame size R8,

68448905 A
 Step 1
Basic assembly UDC- busbar
+H356+H360)

Combi screw

Combi screw

Combi screw

Step 2 Step 3
R- busbar UDC+/R+ busbar

Combi screw
Combi screw

Combi screw
Combi screw
Adding UDC+/R+, UDC- and R- busbars to the adapter (frame size R8,

68448671 C
159

Assembly drawings
160

Assembly drawings
 3AFE68360323 Rev B EN
EFFECTIVE: 14.2.2008

ABB Oy ABB Inc. ABB Beijing Drive Systems Co. Ltd.

AC Drives Automation Technologies No. 1, Block D, A-10 Jiuxianqiao Beilu
P.O. Box 184 Drives & Motors Chaoyang District
FI-00381 HELSINKI 16250 West Glendale Drive Beijing, P.R. China, 100015
FINLAND New Berlin, WI 53151 Telephone +86 10 5821 7788
Telephone +358 10 22 11 USA Fax +86 10 5821 7618
Fax +358 10 22 22681 Telephone 262 785-3200 Internet www.abb.com
Internet www.abb.com 800-HELP-365
Fax 262 780-5135
Internet www.abb.com