DriveIT Low Voltage AC Drive

ACS800 Catalogue Related tools and accessories

3AFE 64572504 REV E EN 17.10.2003

Contents
General
ABB Industrial for drives AC drives
IT

pages 5 5 5

Products
ACS800 for AC motors, compact and complete ACS800 Wall-mounted single drive ACS800 Free standing single drive ACS800 Single drive modules ACS800 Cabinet built single drive ACS800 4-Quadrant drive Standard application software Start-up Assistant Adaptive Programming 6-7 8 - 10 8 - 10 11 - 12 13 - 15 16 - 17 18 19 20

Control Solutions
ABBs ready-made Control Solutions for specific drive applications Centrifuge Control Extruder Control Pump and Fan Control Spinning Control & Traverse Control Crane Drive Control 21 22 22 23 24 25

Others
ACS800 I/O Control Panel Fieldbus Control Dynamic Braking Output filters Programming Tool - DriveAP Integration Tool - DriveOPC Engineering Tool - DriveSize Start-up and Maintenance Tool - DriveWindow 2 Start-up and Maintenance Tool - DriveWindow Light 2.1 Remote Monitoring Tool Energy saving with ACS800 26 27 28 29 - 30 31 - 32 33 34 35 36 37 38 39

3AFE 64572504 REV E EN 17.10.2003

DriveIT Low Voltage AC Drive

ACS800

3AFE 64572504 REV E EN 17.10.2003

DriveIT Low Voltage AC Drive

ACS800

ABB
ABB is one of the largest technology companies in the world with broad industry knowledge and geographic scope. It has about 133,000 employees in around 100 countries and occupies a leading position (1, 2 or 3) in each industry and product areas it serves. ABB offers complete industry and process specific solutions, from products to turnkey projects in utilities, oil, gas and petrochemicals, manufacturing and consumer industries, and process industries. ABB offers world-class collaborative business platforms and solutions based on IndustrialIT open architecture software.

Standardization and an architecture based on open standards increase engineering efficiency, speed of implementation and quality. The final result is higher productivity and more output from your plant. Through versatile connectivity the drives made by ABB can be easily integrated with different process automation systems fulfilling the requirements of Industrial IT. Our DriveIT drive products provide the performance, energy savings and life extension that the customers have come to expect from ABB.

AC drives
AC drives are used to control the speed and torque of a standard induction motor, the workhorse of the industry. ABB is a market leader in both motors and drives worldwide. AC drive technology extends the motor speed range from zero to high above the rated speed, increasing the productivity of the driven process. When a low capacity is enough, the drive reduces the machine speed and saves energy. Accurate speed control of the manufacturing process optimizes the quality of the end product. The Direct Torque Control (DTC) developed by ABB has improved control accuracy by making speed encoders unnecessary.

IndustrialIT for drives

As a key element of its business strategy, ABB has committed to a broad program of product development and positioning under the Industrial IT umbrella. This initiative is geared towards increasing standardization of ABB products as the building blocks of larger solutions, while building in functionality that will allow multiple products to interact seamlessly as components of real-time automation and information systems. At the product level ABB's Industrial IT architecture ensures that ABB products can interoperate perfectly. Only products that satisfy a complete list of requirements stipulated by Industrial IT are certified to bear the Industrial IT enabled symbol, a special mark that indicates that the product can be easily integrated into the Industrial IT architecture, in a plug & produce manner.

3AFE 64572504 REV E EN 17.10.2003

ACS800
up to 2800 kW AC motors, compact and complete.

Common technology for different applications

One of the main benefits of the ACS800 series is a wide range of drive products with common technologies. This includes Start-up Assistant, Adaptive Programming and DTC, common user and process interfaces, software tools for sizing, commissioning and maintenance and common spare parts.

Premium Technology - DTC

The heart of the ACS800 is DTC Direct Torque Control, its first class motor control system. The consistently excellent performance of the ACS800 guarantees that the drive is not the limiting factor in your process. DTC technology is well proven in various applications and demanding environments guaranteeing the high reliability of the drive.

Start-up Assistant
The ABB AC drives have always been top of their class in userfriendliness. The new product series brings a whole new meaning to user-friendliness. Thanks to the Start-up Assistant, the commissioning and tuning of a high performance drive could not be easier.

Adaptive Programming
The ACS800 goes one step further compared to normal parameter programming with the addition of Adaptive Programming. It is like having a small PLC inside your drive. Adaptive Programming needs no additional hardware or software but is always there when needed.

ACS800 voltage power range

Motor [kW] 2800 1900 1450 800 200 110 37 5.5 1.5 1.1 0.55 200 240 380 415 500 690 Supply [V]

Integration and Compact Design

Anything that is required from an AC drive, like EMC and harmonic filters, is inside the drive, so no extra space or cabling is needed. Furthermore, there is always space inside the ACS800 for three option modules for I/O extensions, fieldbuses, pulse encoder interface or a PC connection.

3AFE 64572504 REV E EN 17.10.2003

Environmentally sound products

ABB is a signatory to the ICC (International Chamber of Commerce) Business Charter for Sustainable Development and is working towards fulfilling its requirements. ABB AC drives follow all 16 ICC principles and the basic function of variable speed drives is to minimize the environmental impact by matching the speed of the driven machine to the actual need in the process. This often means that the environmental load reduction in the process is ten times more than the environmental load caused by the manufacture, transport and disposal of the drives. The manufacturing of AC drives complies with ISO 14001 standards.

Technical specifications for the ACS800-01/-02/-04/-07/-17 Mains connection

3-Phase supply voltage: U2IN = 208240 V 10% U3IN = 380415 V 10% U5IN = 380500 V 10% U7IN = 525690 V 10% Frequency: Power factor: 48...63 Hz cos1 = 0.98 (fundamental) cos = 0.93...0.95 (total)

Power factor (ACS800-17): cos1 = 1 (fundamental) cos = 0.99 (total)

Efficiency
At nominal power: ACS800-0x ACS800-17 98% 97%

Motor connection
3-Phase output voltage: 0...U2IN/U3IN/U5IN//U7IN Frequency control: Field weakening point: Motor control software: Torque control: Open loop Closed loop Open loop Closed loop Speed control: Open loop Closed loop Open loop Closed loop 0...300 Hz 0...120 Hz with du/dt filters 8...300 Hz ABBs Direct Torque Control (DTC) Torque step rise time: <5 ms with nominal torque <5 ms with nominal torque Non-linearity: 4% with nominal torque 1% with nominal torque Static accuracy: 10% of motor slip 0.01% of nominal speed Dynamic accuracy: 0.3...0.4%sec. with 100% torque step 0.1...0.2%sec. with 100% torque step

Environmental limits
Ambient temperature: Transportation: Storage: Operation: Operation (ACS800-17): Relative humidity: Cooling method: -40...+70C -40...+70C -15...+50C, no frost allowed 40...50C at reduced output current (1%/1C). 0...+50C 40...50C at reduced output current (1.5%/1C). 5 to 95%, no condensation allowed. Dry clean air 0...1000 m without derating 1000...4000 m with derating (690 V units 1000...2000 m with derating)
3AFE 64572504 REV E EN 17.10.2003

Common software features, please see pages 18 - 20.

Altitude:

ACS800 Wall-mounted single drive

ACS800-01, up to 110 kW

ACS800 Free standing single drive

ACS800-02, up to 500 kW

Compact and Complete single drives

ACS800-01 and -02 single drives offer you all that you need. They are available in IP 21 or IP 55 (ACS800-01 only) degrees of protection. The drives up to 110 kW are compact, wall-mounted ACS800-01 drives and from 90 kW up to 500 kW bookshelf-style ACS800-02 drives with a new innovative free-standing enclosure. The difference between the ACS800-01 and the ACS800-02 is the mechanical construction otherwise the drives are similar.

for harmonic filtering and drive protection, extensive and flexible I/O, user-friendly control panel with a Start-up Assistant feature and a silent long-lifetime cooling fan. If even more features are needed, a wide selection of inbuilt options is available. An enclosure extension is also available for the ACS800-02, further enhancing its versatility. Accessories for the ACS800-01 and -02: Brake chopper EMC filter / two alternatives: EN 61800-3, 2nd environment, unrestricted distribution EN 61800-3, 1st environment, restricted distribution Analogue and digital I/O extension modules Fieldbus modules Pulse encoder interface module Accessories for the ACS800-01: IP 55 Accessories for the ACS800-02: Common mode filters for motor protection Accessories requiring enclosure extension for the ACS800-02: Fuse switch Contactor with emergency stop pushbutton 1 or 2 thermistor relays 3 Pt100 relays Cable top entry and exit Customer terminal block In addition several external accessories available like du/dt filter, brake resistor.

Main standard hardware features:

Common in-built features: IP 21 protection class Compact design Harmonic filtering choke inside Long life time cooling fan and capacitors Extensive, programmable I/O Inputs galvanically isolated Three I/O and fieldbus extension slots inside Alphanumeric, multilingual control panel with a Start-up Assistant feature Large power terminals allowing use of over sized or aluminium cable Additionally in ACS800-02: Free standing Two mounting directions as standard Very narrow bookshelf design

Fits anywhere
Both ACS800-01 and ACS800-02 drives are extremely compact without sacrificing user-friendliness. The ACS800-02 has a unique, extremely compact bookshelf design. When using bookshelf mounting, even side-by-side installation is possible. In addition to bookshelf mounting, the ACS800-02 offers a possibility for flat type mounting enabling you to optimise the width or depth depending on your needs.

Everything inside
From the smallest ACS800-01 to the biggest ACS800-02 there is an extensive selection of in-built features and accessories. The standard features include a choke

3AFE 64572504 REV E EN 17.10.2003

Cooling air flow requirements Type Nominal ratings I cont.max A I

max

No-overload use A P cont.max kW

Light-overload use IN A PN kW

Heavy-duty use I
hd

Noise level

Heat dissipation W 100 100 100 120 140 160 200 250 340 440 530 610 810 1190 1190 1440 2750 3350 3950 5300 6050 6550 7450 7850 8300 100 120 140 160 200 250 340 440 530 610 810 990 1190 1440 1940 2310 3050 3700 4300 6600 7200 8100 8650 9100

Air flow

P hd kW

Frame size

dBA V). 62 62 62 62 62 62 62 62 62 62 65 65 65 65 65 65 71 71 71 72 72 72 72 72 72 62 62 62 62 62 62 62 62 62 62 65 65 65 65 65 65 71 71 71 72 72 72 72 72

m3/h 35 35 35 35 35 69 69 69 103 103 168 168 168 405 405 405 540 540 540 1220 1220 1220 1220 1220 1220 35 35 35 35 35 69 69 69 103 103 168 168 168 405 405 405 540 540 540 1220 1220 1220 1220 1220

Three phase supply voltage 208, 220, 230 or 240 V. The power ratings are valid at nominal voltage (230 ACS800-01-0001-2 5.1 6.5 1.1 4.7 0.75 3.4 0.55 R2 ACS800-01-0002-2 6.5 8.2 1.5 6.0 1.1 4.3 0.75 R2 ACS800-01-0003-2 8.5 10.8 1.5 7.7 1.5 5.7 1.1 R2 ACS800-01-0004-2 10.9 13.8 2.2 10.2 2.2 7.5 1.5 R2 ACS800-01-0005-2 13.9 17.6 3 12.7 3 9.3 2.2 R2 ACS800-01-0006-2 19 24 4 18 4 14 3 R3 ACS800-01-0009-2 25 32 5.5 24 5.5 19 4 R3 ACS800-01-0011-2 34 46 7.5 31 7.5 23 5.5 R3 ACS800-01-0016-2 44 62 11 42 11 32 7.5 R4 ACS800-01-0020-2 55 72 15 50 11 37 7.5 R4 ACS800-01-0025-2 72 86 18.5 69 18.5 49 11 R5 ACS800-01-0030-2 86 112 22 80 22 60 15 R5 ACS800-01-0040-2 103 138 30 94 22 69 18.5 R5 ACS800-01-0050-2 141 164 37 132 37 97 30 R6 ACS800-01-0060-2 166 202 45 155 45 115 30 R6 ACS800-01-0070-2 202 282 55 184 55 141 37 R6 ACS800-02-0080-2 214 326 55 211 55 170 45 R7 ACS800-02-0100-2 253 404 75 248 75 202 55 R7 55 R7 ACS800-02-0120-2 295 432 90 290 90 240 1) ACS800-02-0140-2 405 588 110 396 110 316 90 R8 ACS800-02-0170-2 447 588 132 440 132 340 90 R8 ACS800-02-0210-2 528 588 160 516 160 370 110 R8 ACS800-02-0230-2 613 840 160 598 160 480 132 R8 160 R8 ACS800-02-0260-2 693 1017 200 679 200 590 2) 3) ACS800-02-0300-2 720 1017 200 704 200 635 200 R8 Three phase supply voltage 380, 400 or 415 V. The power ratings are valid at nominal voltage (400 V). ACS800-01-0003-3 5.1 6.5 1.5 4.7 1.5 3.4 1.1 R2 ACS800-01-0004-3 6.5 8.2 2.2 5.9 2.2 4.3 1.5 R2 ACS800-01-0005-3 8.5 10.8 3 7.7 3.0 5.7 2.2 R2 ACS800-01-0006-3 10.9 13.8 4 10.2 4.0 7.5 3.0 R2 ACS800-01-0009-3 13.9 17.6 5.5 12.7 5.5 9.3 4.0 R2 ACS800-01-0011-3 19 24 7.5 18 7.5 14 5.5 R3 ACS800-01-0016-3 25 32 11 24 11 19 7.5 R3 ACS800-01-0020-3 34 46 15 31 15 23 11 R3 ACS800-01-0025-3 44 62 22 41 18.5 32 15 R4 ACS800-01-0030-3 55 72 30 50 22 37 18.5 R4 ACS800-01-0040-3 72 86 37 69 30 49 22 R5 ACS800-01-0050-3 86 112 45 80 37 60 30 R5 ACS800-01-0060-3 103 138 55 94 45 69 37 R5 ACS800-01-0070-3 141 164 75 132 55 97 45 R6 ACS800-01-0100-3 166 202 90 155 75 115 55 R6 ACS800-01-0120-3 202 282 110 184 90 141 75 R6 ACS800-02-0140-3 206 326 110 202 110 163 90 R7 ACS800-02-0170-3 248 404 132 243 132 202 110 R7 1) ACS800-02-0210-3 289 432 160 284 160 240 132 R7 ACS800-02-0260-3 445 588 200 440 200 340 160 R8 ACS800-02-0320-3 521 588 250 516 250 370 200 R8 ACS800-02-0400-3 602 840 315 590 315 477 250 R8 315 R8 ACS800-02-0440-3 693 1017 355 679 355 590 2) ACS800-02-0490-3 720 1017 400 704 400 635 3) 355 R8

Enclosure
Degree of Protection: IP 21 (Standard) IP 55 (Optional) for ACS800-01 Paint color: NCS 1502-Y (RAL 90021/PMS 420C)

Type H1 mm R2 R3 R4 R5 R6 R7 R8
*)

IP 21 H2 mm 370 C) 420 C) 490 C) 602 C) 700 C) N/A N/A W1 mm 165 173 240 265 300 250 A) 347 A) W2 mm N/A N/A N/A N/A N/A 602 793 Depth mm 226 265 274 286 400 520 A) B) 617 A) B) Weight kg 9 12 26 37 67 110 240 Weight with enclosure extension *) kg N/A N/A N/A N/A N/A 234 450 H1 mm 528 528 774 775 923 N/A N/A W1 mm 263 263 377 377 420 N/A N/A

IP 55 Depth mm 242 273 278 308 427 N/A N/A Weight kg 16 18 32 50 77 N/A N/A

405 471 606 739 880 1507 2024

H1 = Height with cable connection box H2 = Height without cable connection box W1 = Width of the standard unit W2 = Width with enclosure extension N/A = not available A) The dimensions apply to bookshelf mounting. In flat type mounting the width and depth change places. B) With enclosure extension the depth is increased by 25 mm due to the switch fuse handle. C) ACS800-01 without cable connection box does not fulfill IP 21 requirements.

Weights are for the basic configuration with switch fuse, but without contactor and other options.

3AFE 64572504 REV E EN 17.10.2003

Cooling air flow requirements Type Nominal ratings I cont.max A I

max

No-overload use A P cont.max kW

Light-overload use IN A PN kW

Heavy-duty use I
hd

Noise level

Heat dissipation W

Air flow

P hd kW

Frame size

dBA

m3/h 35 35 35 35 35 69 69 69 103 103 168 168 168 405 405 405 540 540 540 1220 1220 1220 1220 1220 1220 103 103 103 103 103 103 168 168 405 405 405

Three phase supply voltage 380, 400, 415, 440, 460, 480 or 500 V. The power ratings are valid at nominal voltage (500 V). ACS800-01-0004-5 4.9 6.5 2.2 4.5 2.2 3.4 1.5 R2 62 120 ACS800-01-0005-5 6.2 8.2 3 5.6 3.0 4.2 2.2 R2 62 140 ACS800-01-0006-5 8.1 10.8 4 7.7 4.0 5.6 3.0 R2 62 160 ACS800-01-0009-5 10.5 13.8 5.5 10 5.5 7.5 4.0 R2 62 200 ACS800-01-0011-5 13.2 17.6 7.5 12 7.5 9.2 5.5 R2 62 250 ACS800-01-0016-5 19 24 11 18 11 13 7.5 R3 62 340 ACS800-01-0020-5 25 32 15 23 15 18 11 R3 62 440 ACS800-01-0025-5 34 46 18.5 31 18.5 23 15 R3 62 530 ACS800-01-0030-5 42 62 22 39 22 32 18.5 R4 62 610 ACS800-01-0040-5 48 72 30 44 30 36 22 R4 62 810 ACS800-01-0050-5 65 86 37 61 37 50 30 R5 65 990 ACS800-01-0060-5 79 112 45 75 45 60 37 R5 65 1190 ACS800-01-0070-5 96 138 55 88 55 69 45 R5 65 1440 ACS800-01-0100-5 124 164 75 115 75 88 55 R6 65 1940 ACS800-01-0120-5 157 202 90 145 90 113 75 R6 65 2310 ACS800-01-0140-5 180 282 110 163 110 141 90 R6 65 2810 ACS800-02-0170-5 196 326 132 192 132 162 110 R7 71 3050 ACS800-02-0210-5 245 384 160 240 160 192 132 R7 71 3850 ACS800-02-0260-5 289 432 200 284 200 224 160 R7 71 4550 ACS800-02-0320-5 440 588 250 435 250 340 200 R8 72 6850 ACS800-02-0400-5 515 588 315 510 315 370 250 R8 72 7850 ACS800-02-0440-5 550 840 355 545 355 490 315 R8 72 7600 355 R8 72 8100 ACS800-02-0490-5 602 840 400 590 400 515 2) ACS800-02-0550-5 684 1017 450 670 450 590 2) 400 R8 72 9100 ACS800-02-0610-5 718 1017 500 704 500 632 3) 450 R8 72 9700 Three phase supply voltage 525, 575, 600, 660 or 690 V. The power ratings are valid at nominal voltage (690 V). ACS800-01-0011-7 13 14 11 11.5 7.5 8.5 5.5 R4 62 300 ACS800-01-0016-7 17 19 15 15 11 11 7.5 R4 62 340 ACS800-01-0020-7 22 28 18.5 20 15 15 11 R4 62 440 ACS800-01-0025-7 25 38 22 23 18.5 19 15 R4 62 530 ACS800-01-0030-7 33 44 30 30 22 22 18.5 R4 62 610 ACS800-01-0040-7 36 54 30 34 30 27 22 R4 62 690 ACS800-01-0050-7 51 68 45 46 37 34 30 R5 65 840 ACS800-01-0060-7 57 84 55 52 45 42 37 R5 65 1010 ACS800-01-0070-7 79 104 75 73 55 54 45 R6 65 1220 ACS800-01-0100-7 93 124 90 86 75 62 55 R6 65 1650 ACS800-01-0120-7 113 172 110 108 90 86 75 R6 65 1960 Nominal Ratings: Icont.max: rated current available continuously without overloadability at 40C. Imax: maximum output current. Available for 10 s at start, otherwise as long as allowed by drive temperature. Note: max. motor shaft power is 150% Phd. Typical Ratings: No-overload use Pcont.max: typical motor power in no-overload use. Light-overload use IN: continuous current allowing 110% IN for 1min/ 5 min at 40C. PN: typical motor power in light-overload use. Heavy-duty use Ihd: continuous current allowing 150% Ihd for 1min/ 5 min at 40C. Phd: typical motor power in heavy-duty use. The current ratings are the same regardless of the supply voltage within one voltage range. The ratings apply at 40C ambient temperature. At higher temperatures (up to 50C) the derating is 1%/1C. Notes: 50% overload available if Tamb < 25C. If Tamb = 40C, max overload for 1 min is 37%. 50% overload available if Tamb < 30C. If Tamb = 40C, max overload for 1 min is 40%. 50% overload available if Tamb < 20C. If Tamb = 40C, max overload for 1 min is 30%. Higher value available if output frequency is above 41Hz.

1)

2)

3)

4)

10

3AFE 64572504 REV E EN 17.10.2003

ACS800 Single drive modules

ACS800-04, up to 560 kW

Optimized construction
The ACS800-04 has several benefits that make it the optimal choice for panel builders. No special EMC proof cabinets are needed. In ACS800-04 drives with in-built EMC filtering, both radiated and conducted emissions are restricted to EN 61800-3 limits without the need for any extra hardware. Innovative fixing mechanics which minimize the number of bolts facilitate the attachment of the drive module. Fixing of the control unit and control panel is easy thanks to the DIN rail mounting and new type of mounting platform. The compact size with plenty of built-in options minimizes both space requirements and the amount of assembly work needed.

The need for busbars and cables in the cabinet has been minimized by having the incoming power terminals on the top of the module. This enables use of the optimal cabling route.

Maximised flexibility
Thanks to modular design ACS80004 offers wide variety of installation possibilities. Both bookshelf mounting for optimised width and flat type mounting for optimised depth are available. Main standard hardware features: Optimised design for cabinet assembly EMC compliant module Modular design allowing wide variety of variants Easy access to power terminals Easy access and free location of I/O terminals Compact design Harmonic filtering choke inside Long life time cooling fan and capacitors Extensive, programmable I/O Inputs galvanically isolated Three I/O and fieldbus extension slots inside Large power terminals allowing use of over sized or aluminium cable

There are several other possibilities to adapt the drive module to customer needs as well. As examples are possibility of wall or floor mounting and possibility of changing the outputs from left to right. Naturally also the adaptive software and other standard and optional features of the ACS800 series are available.

Easy cabling
The easily accessible power terminals with plenty of space around them make power cabling for the ACS800-04 easy. Moreover, a separate control unit enables easy access to the I/O terminals. The control unit can be optimally sited inside the cabinet to enable access to the I/O terminals without needing to open the drive module.

Accessories for the ACS800-04 In-built options: Brake chopper EMC filter: EN 61800-3, 2nd environment, unrestricted distribution Common mode filters for motor protection Analogue and digital I/O extension modules Fieldbus modules Pulse encoder interface module Various output busbar options (ACS800-04M) Flat type cabling pedestal enabling sideways mounting (ACS800-04M) Other options: Control panel and mounting platform

3AFE 64572504 REV E EN 17.10.2003

11

Cooling air flow requirements Type Nominal ratings I cont.max A I

max

No-overload use A P cont.max kW

Light-overload use IN A PN kW

Heavy-duty use I
hd

Noise level

Heat dissipation W

Air flow

P hd kW

Frame size

dBA

m3/h 540 540 540 1220 1220 1220 1220 1220 1220 540 540 540 1220 1220 1220 1220 1220 540 540 540 1220 1220 1220 1220 1220 1220 540 540 540 540 1220 1220 1220 1220 1220 1220

Three phase supply voltage 208, 220, 230 or 240 V. The power ratings are valid at nominal voltage (230 V). ACS800-04/04M-0080-2 214 326 55 211 55 170 45 R7 71 2750 ACS800-04/04M-0100-2 253 404 75 248 75 202 55 R7 71 3350 55 R7 71 3950 ACS800-04/04M-0120-2 295 432 90 290 90 240 1) ACS800-04/04M-0140-2 405 588 110 396 110 316 90 R8 72 5300 ACS800-04/04M-0170-2 447 588 132 440 132 340 90 R8 72 6050 ACS800-04/04M-0210-2 528 588 160 516 160 370 110 R8 72 6550 ACS800-04/04M-0230-2 613 840 160 598 160 480 132 R8 72 7450 ACS800-04/04M-0260-2 693 1017 200 679 200 590 2) 160 R8 72 7850 ACS800-04/04M-0300-2 720 1017 200 704 200 635 3) 200 R8 72 8300 Three phase supply voltage 380, 400 or 415 V. The power ratings are valid at nominal voltage (400 V). ACS800-04/04M-0140-3 206 326 110 202 110 163 90 R7 71 3050 ACS800-04/04M-0170-3 248 404 132 243 132 202 110 R7 71 3700 132 R7 71 4300 ACS800-04/04M-0210-3 289 432 160 284 160 240 1) ACS800-04/04M-0260-3 445 588 200 440 200 340 160 R8 72 6600 ACS800-04/04M-0320-3 521 588 250 516 250 370 200 R8 72 7200 ACS800-04/04M-0400-3 602 840 315 590 315 477 250 R8 72 8100 2) ACS800-04/04M-0440-3 693 1017 355 679 355 590 315 R8 72 8650 3) ACS800-04/04M-0490-3 720 1017 400 704 400 635 355 R8 72 9250 Three phase supply voltage 380, 400, 415, 440, 460, 480 or 500 V. The power ratings are valid at nominal voltage (500 V). ACS800-04/04M-0170-5 196 326 132 192 132 162 110 R7 71 3050 ACS800-04/04M-0210-5 245 384 160 240 160 192 132 R7 71 3850 ACS800-04/04M-0260-5 289 432 200 284 200 224 160 R7 71 4550 ACS800-04/04M-0320-5 440 588 250 435 250 340 200 R8 72 6850 ACS800-04/04M-0400-5 515 588 315 510 315 370 250 R8 72 7850 ACS800-04/04M-0440-5 550 840 355 545 355 490 315 R8 72 7600 2) ACS800-04/04M-0490-5 602 840 400 590 400 515 355 R8 72 8100 2) ACS800-04/04M-0550-5 684 1017 450 670 450 590 400 R8 72 9100 3) ACS800-04/04M-0610-5 718 1017 500 704 500 632 450 R8 72 9700 Three phase supply voltage 525, 575, 600, 660 or 690 V. The power ratings are valid at nominal voltage (690 V). ACS800-04/04M-0140-7 134 190 132 125 110 95 90 R7 71 2800 ACS800-04/04M-0170-7 166 263 160 155 132 131 110 R7 71 3750 294 160 165/195 4) 160 147 132 R7 71 4250 ACS800-04/04M-0210-7 166/203 4) ACS800-04/04M-0260-7 175/230 4) 326 160/200 4) 175/212 4) 200 4) 163 160 R7 71 4800 ACS800-04/04M-0320-7 315 433 315 290 250 216 200 R8 72 6150 ACS800-04/04M-0400-7 353 548 355 344 315 274 250 R8 72 6650 ACS800-04/04M-0440-7 396 656 400 387 355 328 315 R8 72 7400 ACS800-04/04M-0490-7 445 775 450 426 400 387 355 R8 72 8450 ACS800-04/04M-0550-7 488 853 500 482 450 426 400 R8 72 8300 ACS800-04/04M-0610-7 560 964 560 537 500 482 450 R8 72 9750 Nominal Ratings: Icont.max : rated current available continuously without overloadability at 40C. IMAX : maximum output current. Available for 10 s at start, otherwise as long as allowed by drive temperature. Note: max. motor shaft power is 150% Phd . Typical Ratings: No-overload use Pcont.max: typical motor power in no-overload use. Light-overload use IN: continuous current allowing 110% IN for 1min/ 5 min at 40C. PN: typical motor power in light-overload use. Heavy-duty use Ihd : continuous current allowing 150% Ihd for 1min/ 5 min at 40C. Phd: typical motor power in heavy-duty use. The current ratings are the same regardless of the supply voltage within one voltage range. The ratings apply at 40C ambient temperature. At higher temperatures (up to 50C) the derating is 1%/1C. Notes: 50% overload available if T amb < 25C. If Tamb = 40C, max overload for 1 min is 37%. 50% overload available if T amb < 30C. If Tamb = 40C, max overload for 1 min is 40%. 50% overload available if T amb < 20C. If Tamb = 40C, max overload for 1 min is 30%.

1)

Enclosure
Degree of Protection: IP 00 Paint color: NCS 1502-Y (RAL 90021/PMS 420C)

2)

3)

Type
4)

Higher value available if output frequency is above 41Hz.

*)

Height mm RDCU control unit *) 282

coming with every unit

Width Depth mm mm 126 41

Bookshelf design
Type R7 R8 Height mm 1121 1558 Width mm 426 571 Depth mm 467 564 Weight kg 100 205

Width with cable connection plate for output cables.

Flat type design

Type R7 R8 Height mm 1152 1589 Width mm 631 779 Depth mm 259 356 Weight kg 100 205

12

3AFE 64572504 REV E EN 17.10.2003

ACS800 Cabinet built single drive

ACS800-07, up to 2800 kW

Customised solutions
ACS800-07 is a cabinet built single drive designed for industrial applications. It covers a wide power range and is very compact, the 2800 kW drive is only 3.2 meters wide. It is available with IP 21, IP 22, IP 42, IP 54 and IP 54R protection classes. The ACS800-07 offers a wide variety of standardized configurations to adapt to different application requirements, from line contactor to the prevention of unexpected motor start, or ATEX approved motor protection. If your application requires more, ABBs application engineering services can add special features to the standard product such as an additional cabinet for customer specific devices to ensure exact suitability for the application.

redundancy with parallel connected units. The rectifier module provides 6- or 12-pulse operation as standard.

Extensive range of features

The ACS800-07 has an extensive range of inbuilt features and accessories. Typical accessory choices include extended I/O and fieldbus options, line contactor, EMC filtering, common mode filtering and du/dt (voltage rise) filtering, all mountable within the single cabinet. Main standard hardware features Compact design IP 21 protection class Inbuilt harmonic filtering choke Fuse switch (frames R6-R8) Main switch (frames nxR8i) Extensive, programmable I/O, 6- or 12-pulse operation (frames nxR8i) Long lifetime cooling fan and capacitors Inputs galvanically isolated I/O and fieldbus extension slots inside Alphanumeric multilingual control panel with Start-up Assistant feature

Smart module concept

The drives up to 500 kW are based on a compact single module including rectifier and inverter. Larger drives consist of separate rectifier and inverter modules, which have plug-in power connectors providing easy maintenance and

Accessories for the ACS800-07: Analogue and digital I/O extension modules ATEX approved motor protection Braking chopper and resistor Cabinet heater Common mode filters for motor protection Customer terminal block Du/dt filters Earth fault monitoring for unearthed network EMC filter Fieldbus modules IP 22, 42, 54 or 54R enclosure classes Line contactor with emergency stop push button Line fuse switch (frames nxR8i) Output for fan motor Prevention of unexpected motor start Pulse encoder interface module Top entry and exit of cables 1 or 2 thermistor relays 3, 5 or 8 Pt100 relays Plus tailor made accessories through ABBs application engineering.

3AFE 64572504 REV E EN 17.10.2003

13

Cooling air flow requirements Type Nominal ratings I cont.max A I max A No-overload use P cont.max kW IN A Light-overload use PN kW I
hd

Heavy-duty use A P hd kW Frame size

Noise level dBA 65 65 65 71 71 71 72 72 72 72 72 73 74 74 74 75 76 76 65 65 65 71 71 71 72 72 72 72 72 72 73 74 74 74 75 76 76 65 65 65 71 71 71 71 72 72 72 72 72 72 73 73 73 74 75 75 76 76 78 78

Heat dissipation kW 1.44 1.94 2.31 3.05 3.70 4.30 6.60 7.20 8.10 8.65 9.10 13.0 17.7 18.9 25.5 28.0 43.7 49.1 1.94 2.31 2.81 3.05 3.85 4.55 6.85 7.85 7.60 8.10 9.10 9.70 14.4 18.6 21.1 26.6 31.5 48.1 57.0 1.22 1.65 1.96 3.00 3.75 4.45 4.80 6.15 6.65 7.40 8.45 8.30 9.75 15.3 18.5 19.4 23.9 29.2 35.4 42.2 56.5 68.3 91.2

Air flow

m3/h 405 405 405 540 540 540 1220 1220 1220 1220 1220 3120 3840 3840 3840 5040 5760 6960 405 405 405 540 540 540 1220 1220 1220 1220 1220 1220 3120 3840 3840 3840 5040 5760 6960 405 405 405 540 540 540 540 1220 1220 1220 1220 1220 1220 3120 3120 3120 3840 5040 5040 6240 6960 9360 10080

Three phase supply voltage 380, 400 or 415 V. The power ratings are valid at nominal voltage (400 V). ACS800-07-0070-3 141 164 75 132 55 97 45 R6 ACS800-07-0100-3 166 202 90 155 75 115 55 R6 ACS800-07-0120-3 202 282 110 184 90 141 75 R6 ACS800-07-0140-3 206 326 110 202 110 163 90 R7 ACS800-07-0170-3 248 404 132 243 132 202 110 R7 132 R7 ACS800-07-0210-3 289 432 160 284 160 240 1) ACS800-07-0260-3 445 588 200 440 200 340 160 R8 ACS800-07-0320-3 521 588 250 516 250 370 200 R8 ACS800-07-0400-3 602 840 315 590 315 477 250 R8 2) ACS800-07-0440-3 693 1017 355 679 355 590 315 R8 ACS800-07-0490-3 720 1017 400 704 400 635 3) 355 R8 ACS800-07-0610-3 879 1313 500 844 500 657 400 1xD4 + 2xR8i ACS800-07-0770-3 1111 1519 630 1067 630 830 450 2xD4 + 2xR8i ACS800-07-0870-3 1255 1876 710 1204 710 938 500 2xD4 + 2xR8i ACS800-07-1030-3 1452 1987 800 1394 800 1086 630 2xD4 + 2xR8i ACS800-07-1230-3 1770 2648 1000 1700 1000 1324 710 2xD4 + 3xR8i ACS800-07-1540-3 2156 2950 1200 2070 1200 1612 900 3xD4 + 3xR8i ACS800-07-1850-3 2663 3983 1450 2557 1450 1992 1120 3xD4 + 4xR8i Three phase supply voltage 380, 400, 415, 440, 460, 480 or 500 V. The power ratings are valid at nominal voltage (500 V). ACS800-07-0100-5 124 164 75 115 75 88 55 R6 ACS800-07-0120-5 157 202 90 145 90 113 75 R6 ACS800-07-0140-5 180 282 110 163 110 141 90 R6 ACS800-07-0170-5 196 326 132 192 132 162 110 R7 ACS800-07-0210-5 245 384 160 240 160 192 132 R7 ACS800-07-0260-5 289 432 200 284 200 224 160 R7 ACS800-07-0320-5 440 588 250 435 250 340 200 R8 ACS800-07-0400-5 515 588 315 510 315 370 250 R8 ACS800-07-0440-5 550 840 355 545 355 490 315 R8 2) ACS800-07-0490-5 602 840 400 590 400 515 355 R8 2) ACS800-07-0550-5 684 1017 450 670 450 590 400 R8 ACS800-07-0610-5 718 1017 500 704 500 632 3) 450 R8 ACS800-07-0760-5 883 1318 630 847 630 659 500 1xD4 + 2xR8i ACS800-07-0910-5 1050 1521 710 1008 710 784 560 2xD4 + 2xR8i ACS800-07-1090-5 1258 1880 900 1208 900 940 630 2xD4 + 2xR8i ACS800-07-1210-5 1372 1989 1000 1317 1000 1025 710 2xD4 + 2xR8i ACS800-07-1540-5 1775 2653 1250 1704 1200 1326 900 2xD4 + 3xR8i ACS800-07-1820-5 2037 2953 1450 1956 1400 1522 1120 3xD4 + 3xR8i ACS800-07-2310-5 2670 3990 1900 2563 1850 1995 1400 3xD4 + 4xR8i Three phase supply voltage 525, 575, 600, 660 or 690 V. The power ratings are valid at nominal voltage (690 V). ACS800-07-0070-7 79 104 75 73 55 54 45 R6 ACS800-07-0100-7 93 124 90 86 75 62 55 R6 ACS800-07-0120-7 113 172 110 108 90 86 75 R6 ACS800-07-0140-7 134 190 132 125 110 95 90 R7 ACS800-07-0170-7 166 263 160 155 132 131 110 R7 ACS800-07-0210-7 166/203 4) 294 160 165/195 4) 160 147 132 R7 ACS800-07-0260-7 175/230 4) 326 160/200 4) 175/212 4) 200 163 160 R7 ACS800-07-0320-7 315 433 315 290 250 216 200 R8 ACS800-07-0400-7 353 548 355 344 315 274 250 R8 ACS800-07-0440-7 396 656 400 387 355 328 315 R8 ACS800-07-0490-7 445 775 450 426 400 387 355 R8 ACS800-07-0550-7 488 853 500 482 450 426 400 R8 ACS800-07-0610-7 560 964 560 537 500 482 450 R8 ACS800-07-0750-7 628 934 630 603 630 467 500 1xD4 + 2xR8i ACS800-07-0870-7 729 1084 710 700 710 542 560 1xD4 + 2xR8i ACS800-07-1060-7 885 1318 800 849 800 659 630 1xD4 + 2xR8i ACS800-07-1160-7 953 1419 900 914 900 710 710 2xD4 + 2xR8i ACS800-07-1500-7 1258 1874 1200 1208 1200 937 900 2xD4 + 3xR8i ACS800-07-1740-7 1414 2107 1400 1358 1400 1053 1000 2xD4 + 3xR8i ACS800-07-2120-7 1774 2643 1700 1703 1700 1322 1250 2xD4 + 4xR8i ACS800-07-2320-7 1866 2780 1900 1792 1800 1390 1400 3xD4 + 4xR8i ACS800-07-3190-7 2665 3970 2600 2559 2500 1985 1900 3xD4 + 6xR8i ACS800-07-3490-7 2770 4127 2800 2659 2700 2063 2100 4xD4 + 6xR8i

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3AFE 64572504 REV E EN 17.10.2003

Nominal Ratings: Icont.max: rated current available continuously without overloadability at 40C. Imax: maximum output current. Available for 10 s at start, otherwise as long as allowed by drive temperature. Note: max. motor shaft power is 150% Phd. Typical Ratings: No-overload use Pcont.max: typical motor power in no-overload use. Light-overload use IN: continuous current allowing 110% IN for 1min/ 5 min at 40C. PN: typical motor power in light-overload use. Heavy-duty use Ihd: continuous current allowing 150% Ihd for 1min/ 5 min at 40C. Phd: typical motor power in heavy-duty use. The current ratings are the same regardless of the supply voltage within one voltage range. The ratings apply at 40C ambient temperature. At higher temperatures (up to 50C) the derating is 1%/1C.

Notes: 1) 50% overload available if Tamb < 25C. If Tamb = 40C, max overload for 1 min is 37%.
2)

50% overload available if Tamb < 30C. If Tamb = 40C, max overload for 1 min is 40%. 50% overload available if Tamb < 20C. If Tamb = 40C, max overload for 1 min is 30%. Higher value available if output frequency is above 41Hz. 630 mm for types ACS800-07-0120-3 and 0140-5 if equipped with du/dt filter.

3)

4)

5)

Enclosure
Degree Protection: Degree of Protection: IP 21 (Standard) IP 22, IP 42, IP 54, IP54R (Optional) Paint color: Light beige RAL 7035 semi-gloss

Frame size R6 R7 R8 1xD4 + 2xR8i 2xD4 + 2xR8i 2xD4 + 3xR8i 2xD4 + 4xR8i 3xD4 + 3xR8i 3xD4 + 4xR8i 3xD4 + 6xR8i 4xD4 + 6xR8i *) mm

Width *)

Width with line fuse switch *) 430 5) 830 830 1730 2030 2230 2630 2630 3030 3430 4030

Height *) Height *) Depth *) Depth top IP 21/22/42 IP 54 entry/exit *) 2130 2130 2130 2130 2130 2130 2130 2130 2130 2130 2130 2315 2315 2315 2315 2315 2315 2315 2315 2315 2315 2315 646 646 646 646 646 646 646 646 646 646 646 646 646 646 730 730 730 730 730 730 730 730

Weight kg 890 1200 1350 1680 1540 1870 2170 2520

Weight (kg) with line fuse switch 300 400 500 1100 1410 1560 1890 1800 2130 2430 2940

1330 1630 1830 2230 2030 2430 2830 3230

3AFE 64572504 REV E EN 17.10.2003

15

ACS800 4-Quadrant drive

Air cooled regenerative drive. ACS800-17, up to 1120 kW

Complete 4-Quadrant drive

The high performance ACS800-17 4-Quadrant drive allows full power flow in motoring and generating. Transition between modes is fast due to the ultrafast DTC control method. Stepping from Pn to -Pn or vice versa takes only few milliseconds. No dead time in transition is needed. The drive gives full output voltage and even more. Output voltage can be boosted, which means that 100% output voltage is available even when the input voltage is 90%.

Energy savings
Most of the motor drive costs are energy costs. Often the investment is only a small fraction of total costs. Compared with the other braking methods like mechanical and resistor braking, the energy savings can be significant. Braking resistors also take up installation space and the handling of waste heat can be a problem.

Excellent supply side features

The unique DTC/LCL filter features: Fundamental power factor unity Extremely low current and voltage harmonics Very small commutating notches DTC type control has several advantages: Ultra-fast response to changes No fixed switching frequency, resonating risk avoided Switching only when needed, less switching stress Other features resulting from the DTCs high stability: Needs no tuning according to grid inductance Plug and play line inverter

Easy and flexible

The standard software contains the Adaptive Programming feature that enables the user to make small modifications to the software. Other software alternatives are also available for special applications. There are two features that facilitate commissioning: the line converter is a plug and play product, so no settings are needed. The motor inverter parameters can be easily adjusted from control panel with the new interactive software, Startup Assistant.

Friendly but robust power line

Power companies set limits for the permissible harmonic content of current and voltage in order to prevent damage to equipment in the same environment. The ACS800-17 removes low order harmonics with line converter DTC control and high order harmonics with an LCL filter. The result is very clean power for 6, 12, 18 and 24 pulse rectifier solutions. The ultrafast DTC can even compensate for fast variations in line voltage. There is no risk of component damage due to voltage drops as in thyristor-based rectifiers in AC and DC drives.
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3AFE 64572504 REV E EN 17.10.2003

LCL filter
ACS800 main modules

Line inverter (rectifier)

Motor inverter

Motor

Excellent motor side features

The active line rectifier together with DTC ensures robust behaviour even in demanding conditions. Torque is always stable even with unstable net voltage Excellent line voltage dip proof operation Extremely fast and smooth operation in motoringregenerating-motoring transitions
Nominal ratings Type I
cont max

The motor converter uses the standard ACS800 DTC motor control. This ultrafast control loop enables fast responses to load and line voltage changes. The adjustable DC voltage boost function makes it possible to shift the field weakening point to higher frequencies. In many cases this feature enables a one size smaller motor to be selected.

In moderate voltage drops the control can maintain full DC voltage and the motors get full power. In heavy voltage drops power cannot be obtained from the line, but the drive can be kept ready to produce power immediately when voltage returns. The time between maximum motoring and regenerating power is in the range of milliseconds.

150% duty cycle I_4/5 min A (AC) I_1/5 min A (AC)

200% duty cycle I_50/60 s A (AC) I_10/60 s I max A (AC) Frame size

Information for units and cabinets Height 1) mm Width 2) mm Weight kg Noise level dB Ploss kW 4.1 6.0 7.3 8.9 11.2 13.9 22.0 27.2 31.7 39.3 3.4 4.9 7.2 8.8 11.1 13.7 17.4 27.3 31.7 38.9 48.7 7.2 8.8 10.9 13.4 17.2 27.0 31.3 38.1 48.7 Air flow m3/h 1920 3650 3650 3650 3650 3650 7280 7280 10330 10330 1920 1920 3650 3650 3650 3650 3650 7280 7280 10330 10330 3650 3650 3650 3650 3650 7280 7280 10330 10330

P cont max kW

Three phase supply voltage 380, 400 or 415 V. The power ratings are valid at nominal voltage (400 V). ACS800-17-0120-3 178 90 147 221 147 294 R7i 2130 730 305 63 ACS800-17-0185-3 259 132 194 291 178 356 R8i 2130 1230 625 63 ACS800-17-0225-3 312 160 234 351 216 432 R8i 2130 1230 625 63 ACS800-17-0265-3 379 200 284 426 260 520 R8i 2130 1230 625 63 ACS800-17-0335-3 474 250 356 533 316 632 R9i 2130 1230 655 63 ACS800-17-0405-3 576 315 432 648 395 790 R9i 2130 1230 655 63 ACS800-17-0630-3 907 500 680 1020 600 1200 R11i 2130 3630 1490 68 ACS800-17-0765-3 1094 630 821 1231 751 1502 R11i 2130 3630 1490 68 ACS800-17-0935-3 1336 710 1002 1503 901 1802 R12i 2130 4630 2530 71 ACS800-17-1125-3 1624 900 1218 1827 1126 2252 R12i 2130 4630 2530 71 Three phase supply voltage 380, 400, 415, 440, 460, 480 or 500 V. The power ratings are valid at nominal voltage (500 V). ACS800-17-0100-5 112 75 84 126 84 168 R6i 2130 730 305 63 ACS800-17-0140-5 164 110 135 203 135 270 R7i 2130 730 305 63 ACS800-17-0215-5 246 160 185 277 164 328 R8i 2130 1230 625 63 ACS800-17-0255-5 295 200 221 332 200 400 R8i 2130 1230 625 63 ACS800-17-0325-5 368 250 276 414 240 480 R8i 2130 1230 625 63 ACS800-17-0395-5 448 315 336 504 300 600 R9i 2130 1230 655 63 ACS800-17-0495-5 565 400 424 636 365 730 R9i 2130 1230 655 63 ACS800-17-0770-5 887 630 665 998 570 1140 R11i 2130 3630 1490 68 ACS800-17-0935-5 1073 710 805 1208 694 1388 R11i 2130 3630 1490 68 ACS800-17-1090-5 1263 900 947 1421 855 1710 R12i 2130 4630 2530 71 ACS800-17-1385-5 1593 1120 1195 1793 1040 2080 R12i 2130 4630 2530 71 Three phase supply voltage 525, 575, 600, 660 or 690 V. The power ratings are valid at nominal voltage (690 V). ACS800-17-0205-7 176 160 132 198 127 254 R8i 2130 1230 625 63 ACS800-17-0255-7 210 200 158 236 150 300 R8i 2130 1230 625 63 ACS800-17-0315-7 264 250 198 297 179 358 R8i 2130 1230 625 63 ACS800-17-0375-7 310 315 233 349 225 450 R9i 2130 1230 655 63 ACS800-17-0485-7 410 400 308 461 265 530 R9i 2130 1230 655 63 ACS800-17-0750-7 630 630 473 709 428 856 R11i 2130 3630 1730 68 ACS800-17-0900-7 755 710 566 849 504 1008 R11i 2130 3630 1730 68 ACS800-17-1045-7 874 900 656 983 641 1282 R12i 2130 4630 2530 71 ACS800-17-1385-7 1156 1120 867 1301 755 1510 R12i 2130 4630 2530 71

Notes: 1) Cabinet height is 2130 mm, 2072 mm for IP 54R 2) An additional 400 mm is required in frame size R11 with top exits An additional 600 mm is required in frame size R12 with top exits Cabinet depth is 731 mm Dimensions limit the number of options in frames R6 / R7 / R8 / R9.

Enclosure
Degree of Protection: IP 21 (Standard) IP 22, IP 42, IP 54R (Optional) Paint color: Light beige RAL 7035 semi-gloss

Alternatives in reducing line harmonics

6 pulse rectifier 12 pulse rectifier 18 pulse rectifier ACS800-17

Transformer and cabling simple

Transformer and cabling complicated

Transformer and cabling complicated

Transformer and cabling simple

Current very distorted >Ithd 30%

Current distorted >Ithd 12%

Current wave form good >Ithd 6%

Current wave form best Ithd 4%

3AFE 64572504 REV E EN 17.10.2003

17

Standard application software

Based on the Direct Torque Control technology, the ACS800 offers highly advanced features as standard. ACS800 standard application software provides solution virtually to all AC drives applications.

Software features
A complete set of standard software features offers premium functionality and flexibility. Accurate speed control Accurate torque control without speed feedback Adaptive Programming Automatic reset Automatic start Constant speeds Controlled torque at zero speed DC hold DC Magnetizing Diagnostics Flux braking Flux optimization IR compensation Master/follower control Mechanical brake control Motor identification Parameter lock Power loss ride-through Process PID control Programmable I/O Scalar control Speed controller tuning Start-up Assistant Trim function User-selectable acceleration and decelaration ramps

Pre-programmed protection functions

A wide feature range provides protection for the drive, motor and the process. Ambient temperature DC overvoltage DC undervoltage Drive temperature Input phase loss Overcurrent Power limits Short circuit

The standard application macros

The ACS800 features built-in, preprogrammed application macros for configuration of such parameters as inputs, outputs and signal processing. FACTORY SETTINGS for basic industrilal applications HAND/AUTO CONTROL for local and remote operation PID CONTROL for closed loop processes SEQUENTIAL CONTROL for repetitive cycles TORQUE CONTROL for processes where torque control is required USER MACRO 1 & 2 for users own parameter settings

Programmable protection functions

Adjustable power limits Control signal supervision Critical frequencies lock-out Current and torque limits Earth fault protection External fault Motor phase loss Motor stall protection Motor thermal protection Motor underload protection Panel loss

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3AFE 64572504 REV E EN 17.10.2003

Start-up Assistant
The easy way of commissioning.
L <- 0.0 rpm 0 ** INFORMATION ** Press FUNC to start guided motor set up

Basic set up LANGUAGE ? [ENGLISH] Select(arrows)+ENTER

Motor set up MOTOR NOM CURRENT ? 0A Press FUNC for info

READY TO START READY TO START

ABB AC drives have always been top of their class in user- friendliness. The new ACS800 AC drive brings a whole new meaning to user-friendliness. Thanks to the Start-up Assistant, the commissioning and tuning of a high performance drive could not be easier.

All this saves your time enabling you to concentrate on essential issues.

Features
Easy and fast commissioning procedure Intelligent guide to assist you through the commissioning Your own language On-line info system always available The ACS800 offers you all this as a standard feature.

On-line info system

To make it easier and more informative, there is an on-line info system available at each step helping to set the correct values for each parameter. Just one push of the button and useful hints and information for that specific stage are available to you. Each step also includes reference to the printed manuals if even more specific information is needed.

Faster and easier commissioning

When you turn on your drive for the first time the Start-up Assistant actively guides you through the commissioning procedure. You do not need to worry which parameters should be set, the Start-up Assistant does that. To ensure a convenient commissioning procedure the Start-up Assistant speaks 14 different languages. It asks for motor nominal values as well as the I/O configuration and application specific parameters like acceleration and deceleration times. After this, the ACS800 is ready for your process.

3AFE 64572504 REV E EN 17.10.2003

19

Adaptive Programming
No extra hardware or software needed.

The freely programmable I/O and the extensive parameter selections make the ACS800 highly suitable as such for most applications. The ACS800, however, goes one step further with the addition of Adaptive Programming as a standard feature. It is like having a small PLC inside your drive. Adaptive Programming needs no additional hardware or software but is always there when needed.

Programming the new ACS800 could not be any easier. All you need is the control panel and the programming is as simple as setting parameters. With Adaptive Programming the user is really able to modify the new ACS800 to suit the process perfectly. Because no extra hardware or software is needed, the programming can be done in a few minutes even on-site.

Features
15 programmable function blocks Available functions: Logical: AND, OR and XOR Mathematical: add, mul, div, abs, max and min Other: timer, switch, comparator, filter, SR, PI and user defined warnings or faults Freely definable execution order Easy documentation The ACS800 offers you all this as a standard feature!

Programming done in a few minutes

Adaptive Programming consists of a set of blocks, which can be programmed to perform any of the predefined set of functions. All the common functions for making a real block program are available to you. The user can freely define inputs to the blocks, wiring between the blocks and connections to the drive I/O or to the drive control. In this way the user is able to create new input and/or output signals and modify the drives speed or torque control.

Optimal adaptability
Small PLC inside Program your drive on-site during commissioning Create your own I/O signals, modify speed or torque reference chain or set a timer Do it without any additional hardware or software As simple as setting a parameter There is also a PC tool available for Adaptive Programming.

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3AFE 64572504 REV E EN 17.10.2003

Control Solutions
ABBs ready-made Control Solutions for specific drive applications.

Centrifuge Control
Practical programmable sequences for conventional centrifuges. Decanter Control for accurate speed difference control of two shafts.

Spinning Control & Traverse Control

Spinning Control and Traverse Control make a perfect pair for precise control of spinning and traverse drives in textile machines.

The main advantages of ABBs control solutions:

Application-dedicated features Improved production No external PLC User-friendly Easy to use Energy savings Smooth power loss ridethrough Reduced costs Adaptive protections

Extruder Control
High starting torque, accurate speed/torque control and overload protection for demanding extruder applications.

Crane Drive Control

The cost effective crane drive with optimal operational safety and outstanding performance already built in.

Pump and Fan Control

Pump and Fan Control provides better flow control and cost savings up to 5 parallel motors in various industrial pump and fan applications.

Master/Follower Control
Reliable control via fibre optic link of several drives when motor shafts are coupled together.

3AFE 64572504 REV E EN 17.10.2003

21

Control Solutions
Centrifuge Control.

Centrifuge Control features

Centrifugation patterns Common DC-link possibility

Additional Decanter Control features

Direct communication between bowl and scroll drive through optical fibres Automatic scaling of process speed based on the given gear box and belt ratio Speed difference control Load compensation of scroll drive

Centrifuge & Decanter Centrifuge as one

The Centrifuge application consists of programmable sequences for centrifuges e.g. in the food and beverage industries. The Decanter Control is integrated with the Centrifuge Control. This feature can be applied in all applications needing co-ordinated speed difference control.

A decanter (separator, centrifuge) is used to separate solid particles from fluid. In a typical decanter two rotating shafts called bowl and scroll are used. Direct Torque Control enables smooth operation with different kinds of fluid viscosity and automatically adapts to load changes.

Control Solutions
Extruder Control.
AC drives designed for extruder applications
An extruder is an application where material typically in granulate or pulverized form is driven through a screw to achieve a continuous material form to be further modified in the manufacturing process. Due to the material characteristics high starting torque is often needed. The screw and also the delicate mechanical parts of the machinery need to be protected against overload.

Extruder application features

High starting torque, excellent speed accuracy without encoder Adaptive torque limitation feature Two sets of parameterised stall protection functions Digital potentiometer with two different accelerating and decelerating ramp times Four control locations

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3AFE 64572504 REV E EN 17.10.2003

Control Solutions
Pump and Fan Control.

Introduction
There are many pump and fan installations with quite extensive flow variations. Such are water and sewage systems, air conditioning, district heating and different industrial applications. A common solution for these is to run several fixed speed pumps or fans in parallel and flow control is made by switching them on and off. This

kind of control causes discontinuous flow and there is a risk of damage caused by pressure strokes. Better flow control can be achieved with variable speed drives. The cost can be reduced by putting a variable speed drive to one unit only and controlling the fixed speed units with the Pump and Fan Control application, PFC.

Features
The maximum number of units (pumps or fans) in parallel is 5 (1 with speed control and 4 with fixed speed) PI controller with setpoint adjustment internal or external actual value with five selectable units Setpoint steps for 4 motors Sleep and wake up level and delay settings Start and low frequency settings for 4 motors Start and stop delays Autochange delay and level settings Automatic interlocking between motors

Mains 400 V/50 Hz

Alternation switchgear cabinet

Pressure transducer 0...10 bar 4...20 mA

M1 7.5 kW 1450 rpm 14.8 A

M2 7.5 kW 1450 rpm 14.8 A

Pumping station for two pumps. ACS800 is installed inside the alternation switchgear cabinet.

3AFE 64572504 REV E EN 17.10.2003

23

Control Solutions
Spinning Control & Traverse Control.

Doff

ACS800 Spinning Control is a solution for the precise control of spinning machine and for preventing yarn breakages. The ACS800 drive features allow maximum production and prevent yarn breakages during start-up and any power losses. The Traverse Control is designed to run traverse drives guiding yarn into a package in textile machines. To avoid layering at the reversal points of the yarn guide an instantaneous change, a P-jump, is made at speed.

ACS800 Spinning Control

Yarn Bobbin

Speed Time Pattern Motor

Gear

The principle of the Spinning Control.

ACS800 with Standard program

ACS800 Traverse Control P-jump function

Features for Spinning Control:

Wobbulation function Shiftwise production calculation Automatic doff (pattern) selection 4 speed time patterns
Yarn

Yarn package

Gear Motor Yarn guide

Features for Traverse Control:

Wide selection for base speed reference Dynamic quick steps, real or proportional steps

Gear Motor

The principle of the Traverse Control.

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3AFE 64572504 REV E EN 17.10.2003

Control Solutions
Crane Drive Control.

Standard ready-to-use crane drive solution with optimal operational safety and outstanding crane drive performance.

Flexible user interface

Joystick interface, with step or continuous speed reference Pendant control, with built in motor potentiometer Radio control, with step or continuous speed reference Fieldbus communication, for connection to PLC Limit switches, to ensure the crane works within a safe operation area

Outstanding performance
Start and stop logic ensures that torque is available before the brake is released 4 different ramp times. Individual settings for acceleration and deceleration ramp times in both directions Torque memory presets torque when starting the hoist with suspended load, used for avoiding load drops when mechanical brake is released Power optimization ensures maximum hoist speed relative to the load. This optimizes the cranes capacity Optical master-follower link, used for load sharing between two mechanically connected motors. This can also be used for redundancy applications Electrical shaft function, for synchronizing two drives without mechanical connection. Adjustable control for position correction

Crane Drive Control

The cost-effective crane drive with safety and performance already built in. Easy installation and start-up reduces the total project costs Ready to use with proven modular crane functionality Accurate and fast torque response increases the operational productivity Smooth crane operation reduces maintenance and damage costs Available as single drive and multi drive with dynamic and regenerative braking

Operational safety
Mechanical brake functions for controlling and supervising the brake Adjustable fast stop procedure in case of overload or slack rope etc. Torque proving ensures that the motor has produced sufficient torque when opening the brakes Speed monitoring ensures that the speed stays within given limits. Also zero speed detection Torque monitoring supervises the correlation between the speed ordered and actual motor speed

3AFE 64572504 REV E EN 17.10.2003

25

ACS800 I/O

Analog and digital I/O channels are used for different functions such as control, monitoring and measurement purposes (e.g. motor temperature).

In addition, optional I/O extension modules are available providing additional analog or digital connections.
X20 1 2 X21 1 2 3 4 5 6 7
rpm

Standard I/O on RMIO-01 Board

3 analog inputs: differential, common mode voltage, galvanically isolated as a group. - One 0(2)...10 V, resolution 12 bit - Two 0(4)...20 mA, resolution 12 bit 2 analog outputs: - 0(4)...20 mA, resolution 10 bit

Below are the standard control connections of the ACS800 single drive with Factory Macro. For other ACS800 application macros the functions may be different.
VREF- Reference voltage -10 VDC, 1 kohm < RL < AGND 10 kohm VREF+ Reference voltage 10 VDC, 1 kohm AGND < RL < 10 kohm AI1+ AI1AI2+ AI2AI3+ AI3AO1+ AO1AO2+ AO2DI1 DI2 DI3 DI4 DI5 DI6 Speed reference 0(2) ... 10 V, Rin > 200 kohm By default, not in use. 0(4) ... 20 mA, Rin = 100 ohm By default, not in use. 0(4) ... 20 mA, Rin = 100 ohm
^ Motor speed 0(4)...20 mA = 0...motor nom. speed, RL < 700 ohm ^ Output current 0(4)...20 mA = 0...motor nom. current, RL < 700 ohm

7 digital inputs: galvanically isolated as a group (can be split in two groups) - Input voltage 24 V - Filtering (HW) time 1 ms
3 relay (digital) outputs: - Switchover contact - 24 V or 115/230 V AC - Max. 2 A Reference voltage output: - 10 V 0.5%, max. 10 mA Auxiliary power output: - +24 V 10%, max. 250 mA

8 9 10 11 12 X22 1 2 3 4 5 6 7 8 9 10 11 X23 1 2 X25 1 2 3 X26 1 2 3 X27 1 2 3

Stop/Start Forward/Reverse By default, not in use. Acceleration & deceleration select Constant speed select Constant speed select

Optional I/O
Analog I/O Extension Module RAIO-01
2 analog inputs: galvanically isolated from 24 V supply and ground - 0(2)...10 V, 0(4)... 20 mA or 0...2 V, resolution 12 bits 2 analog outputs: galvanically isolated from 24 V supply and ground - 0(4)...20 mA, resolution 12 bit

+24VD +24 V DC max. 100 mA +24VD DGND1 Digital ground DGND2 Digital ground Start interlock (0 = stop) DIIL +24V GND RO11 RO12 RO13 RO21 RO22 RO23 RO31 RO32 RO33 Relay output 3: fault (-1) Relay output 2: running Auxiliary voltage output, non-isolated, 24 V DC 250 mA Relay output 1: ready

Digital I/O Extension Module RDIO-01

3 digital inputs: individually galvanically isolated - Signal level 24 to 250 V or 115/230 V AC 2 relay (digital) outputs: - Switchover contact - 24 V or 115/230 V AC - Max. 2 A

Pulse Encoder Interface Module RTAC-01

1 incremental encoder input: - Channels A, B and Z (zero pulse) - Signal level and power supply for the encoder is 24 or 15 V - Single ended or differential inputs - Maximum input frequency 200 kHz

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3AFE 64572504 REV E EN 17.10.2003

Control Panel
ACS800 with user-friendly functionality.

Fault memory

A built-in fault memory stores information relating to the latest 64 faults, each with a time stamp.

The ACS800 control panel provides a great deal of information in plain, easy-to-understand language.

Parameter copying

Parameter copy feature allows all drive parameters to be copied from one frequency converter to another to simplify commissioning.

Actual value
The ACS800 control panel can display three separate actual values simultaneously. Examples of these are: Motor speed Frequency Current Torque Power References DC bus voltage Output voltage Heatsink temperature Operating hours Kilowatt hours

Centralised control

One panel can control up to 31 drives.

Simple arrangement

Parameters are organised into groups for easy programming.

Control Panel
Multilingual alphanumeric display (4 lines x 20 characters) plain text messages in 14 languages. Intelligent removable control panel can be mounted on the ACS800 enclosure or remotely.
Start-up Assistant

Easy commissioning with the Start-up Assistant. The Start-up Assistant actively guides you through the commissioning procedure.
Adaptive Programming

Local drive operation from control panel, including LOCAL/REMOTE selection, START/STOP, RESET, MOTOR ROTATION DIRECTION and REFERENCE setting.

No extra hardware or software required for Adaptive Programming.

3AFE 64572504 REV E EN 17.10.2003

27

Fieldbus Control
Gateway to your process.

ABB AC drives have the connectivity to major automation systems. This is achieved with a dedicated gateway concept between the fieldbus systems and ABB drives. The fieldbus gateway is a snap-on module that can be easily mounted inside the drive. As a result of the wide range of fieldbus gateways, your choice for an automation system becomes independent of your decision to use first-class ABB AC drives.

Drive diagnostics Accurate and reliable diagnostic information can be obtained via the drive Alarm, Limit and Fault Words reducing the down time of the drive and therefore also the down time of the manufacturing process. Drive parameter handling Total integration of the drives in the production process is achieved by single parameter read/write up to complete parameter set-up or download. Easy to expand Serial communication simplifies the latest trend of modular machine design enabling expansion of the installation at a later stage with low effort.

Reduced Installation and Engineering Effort

Cabling Substituting the large amount of conventional Drive Control cabling with a single twisted pair reduces costs and increases system reliability. Design The use of Fieldbus Control reduces engineering time at installation due to the modular structure of the hardware and software. Commissioning and assembly The modular machine configuration allows pre-commissioning of single machine sections and provides easy and fast assembly of the complete installation.

Manufacturing Flexibility
Drive control The drive Control Word (16 bit) provides a wide variety of functions from Start, Stop and Reset to Ramp Generator control. Typical setpoint values like Speed, Torque and Position can be transmitted to the drive with 15 bit accuracy. Drive monitoring A set of drive parameters and/or actual signals, like torque, speed, position, current etc., can be selected for cyclic data transfer providing fast data for operators and the manufacturing process.

Currently Available Gateways

PROFIBUS-DP DeviceNet CANopen ControlNet ModbusPlus LONWORKS Modbus Ethernet InterBus-S

28

3AFE 64572504 REV E EN 17.10.2003

Dynamic Braking
Brake Choppers and Resistors.
Brake Chopper
The ACS800 series has in-built brake choppers for all types. Therefore, no additional space or installation time is needed. The brake chopper is part of the standard delivery for the R2 and R3 frames. For the other frames a brake chopper is a selectable option. Braking control is integrated into the ACS800 series. It controls the braking, supervises the system status and detects failures such as brake resistor and resistor cable short circuits, chopper short circuit, and calculated resistor overtemperature. For ACS800 units, no separate fuses in the brake circuit are required if the following conditions are met: The ACS800 mains cable is protected with fuses No mains cable/fuse overrating takes place

Brake Resistor
The SACE/SAFUR brake resistors are separately available for all ACS800 types. Resistors other than the standard resistors may be used providing the specified resistance value is not decreased, and the heat dissipation capacity of the resistor is sufficient for the drive application.

UN = 230 V (208, 220, 230, 240 V)

ACS800 type
Brake Chopper Power

Brake Resistor(s) Type SACE08RE44 SACE08RE44 SACE08RE44 SACE08RE44 SACE15RE22 SACE15RE22 SACE15RE22 SACE15RE13 SAFUR90F575 SAFUR90F575 SAFUR80F500 SAFUR125F500 SAFUR125F500 2 x SAFUR125F500 2 x SAFUR125F500 2 x SAFUR125F500 R [Ohm] 44 44 44 44 22 22 22 13 8 8 6 4 4 2 2 2 Er [kJ] 248 248 248 248 496 496 496 496 1800 1800 2400 3600 3600 7200 7200 7200 P rcont [kW] 1 1 1 1 2 2 2 2 4.5 4.5 6 9 9 18 18 18

ACS800 type

Brake Chopper Power 5 / 60 s 10 / 60 s 30/60 s Continuous Pbr5 [kW] Pbr10 [kW] Pbr30 [kW] Pbrcont [kW] Type

Brake Resistor(s) R [Ohm] 1.78 1.78 1.35 0.89 0.89 0.89 0.89 0.45 0.45 Er [kJ] 3600 3600 10800 7200 7200 7200 7200 14400 14400 P rcont [kW] 9 9 27 18 18 18 18 36 36

Continuous Pbrcont [kW] ACS800-01-0001-2 ACS800-01-0002-2 ACS800-01-0003-2 ACS800-01-0004-2 ACS800-01-0005-2 ACS800-01-0006-2 ACS800-01-0009-2 ACS800-01-0011-2 ACS800-01-0016-2 ACS800-01-0020-2 ACS800-01-0025-2 ACS800-01-0030-2 ACS800-01-0040-2 ACS800-01-0050-2 ACS800-01-0060-2 ACS800-01-0070-2 0.6 0.8 1.1 1.5 2.2 3 4 5.5 11 17 23 28 33 45 56 68

ACS800-02/04-0080-2 ACS800-02/04-0100-2 ACS800-02/04-0120-2 ACS800-02/04-0140-2 ACS800-02/04-0170-2 ACS800-02/04-0210-2 ACS800-02/04-0230-2 ACS800-02/04-0260-2 ACS800-02/04-0300-2

68 83 105 135 135 165 165 223 223

68 83 67 135 135 165 165 170 170

68 83 60 135 135 165 165 125 125

54 54 40 84 84 98 113 64 64

SAFUR 160F380 SAFUR 160F380 2xSAFUR200F500 2xSAFUR160F380 2xSAFUR160F380 2xSAFUR160F380 2xSAFUR160F380 4xSAFUR160F380 4xSAFUR160F380

UN = 400 V (380, 400, 415 V)

ACS800 type
Brake Chopper Power

Brake Resistor(s) Type SACE08RE44 SACE08RE44 SACE08RE44 SACE08RE44 SACE08RE44 SACE15RE22 SACE15RE22 SACE15RE22 SACE15RE13 SACE15RE13 SAFUR90F575 SAFUR90F575 SAFUR90F575 SAFUR80F500 SAFUR125F500 SAFUR125F500 R [Ohm] 44 44 44 44 44 22 22 22 13 13 8 8 8 6 4 4 Er [kJ] 248 248 248 248 248 496 496 496 496 496 1800 1800 1800 2400 3600 3600 P rcont [kW] 1 1 1 1 1 2 2 2 2 2 4.5 4.5 4.5 6 9 9

ACS800 type

Brake Chopper Power 5 / 60 s 10 / 60 s 30/60 s Continuous Pbr5 [kW] Pbr10 [kW] Pbr30 [kW] Pbrcont [kW]

Brake Resistor(s) Type SAFUR200F500 SAFUR200F500 SAFUR200F500 2XSAFUR210F575 2xSAFUR200F500 4xSAFUR125F500 4xSAFUR210F575 4xSAFUR210F575 R [Ohm] 2.70 2.70 2.70 1.70 1.35 1.00 0.85 0.85 Er [kJ] 5400 5400 5400 8400 10800 14400 16800 16800 P rcont [kW] 13.5 13.5 13.5 21 27 36 42 42

Continuous Pbrcont [kW] ACS800-01-0003-3 ACS800-01-0004-3 ACS800-01-0005-3 ACS800-01-0006-3 ACS800-01-0009-3 ACS800-01-0011-3 ACS800-01-0016-3 ACS800-01-0020-3 ACS800-01-0025-3 ACS800-01-0030-3 ACS800-01-0040-3 ACS800-01-0050-3 ACS800-01-0060-3 ACS800-01/07-0070-3 ACS800-01/07-0100-3 ACS800-01/07-0120-3 1.1 1.5 2.2 3 4 5.5 7.5 11 23 28 33 45 56 68 83 113

ACS800-02/04/07-0140-3 ACS800-02/04/07-0170-3 ACS800-02/04/07-0210-3 ACS800-02/04/07-0260-3 ACS800-02/04/07-0320-3 ACS800-02/04/07-0400-3 ACS800-02/04/07-0440-3 ACS800-02/04/07-0490-3

135 165 165 240 300 375 473 500

135 150 150 240 300 375 355 355

100 100 100 240 300 273 237 237

80 80 80 173 143 130 120 120

3AFE 64572504 REV E EN 17.10.2003

29

UN = 500 V (380, 400, 415, 440, 460, 480 and 500 V)

ACS800 type
Brake Chopper Power

Brake Resistor(s) Type SACE08RE44 SACE08RE44 SACE08RE44 SACE08RE44 SACE08RE44 SACE15RE22 SACE15RE22 SACE15RE22 SACE15RE13 SACE15RE13 SAFUR90F575 SAFUR90F575 SAFUR90F575 SAFUR125F500 SAFUR125F500 SAFUR125F500 R [Ohm] 44 44 44 44 44 22 22 22 13 13 8 8 8 4 4 4 Er [kJ] 248 248 248 248 248 496 496 496 496 496 1800 1800 1800 3600 3600 3600 P rcont [kW] 1 1 1 1 1 2 2 2 2 2 4.5 4.5 4.5 9 9 9

ACS800 type

Brake Chopper Power 5 / 60 s 10 / 60 s 30/60 s Continuous Pbr5 [kW] Pbr10 [kW] Pbr30 [kW] Pbrcont [kW]

Brake Resistor(s) Type SAFUR200F500 SAFUR200F500 SAFUR200F500 2xSAFUR125F500 2XSAFUR210F575 2xSAFUR200F500 2xSAFUR200F500 4xSAFUR125F500 4xSAFUR125F500 R [Ohm] 2.70 2.70 2.70 2.00 1.70 1.35 1.35 1.00 1.00 Er [kJ] 5400 5400 5400 7200 8400 10800 10800 14400 14400 P rcont [kW] 13.5 13.5 13.5 18 21 27 27 36 36

Continuous Pbrcont [kW] ACS800-01-0004-5 ACS800-01-0005-5 ACS800-01-0006-5 ACS800-01-0009-5 ACS800-01-0011-5 ACS800-01-0016-5 ACS800-01-0020-5 ACS800-01-0025-5 ACS800-01-0030-5 ACS800-01-0040-5 ACS800-01-0050-5 ACS800-01-0060-5 ACS800-01-0070-5 ACS800-01/07-0100-5 ACS800-01/07-0120-5 ACS800-01/07-0140-5 1.5 2.2 3 4 5.5 7.5 11 15 28 33 45 56 68 83 113 135

ACS800-02/04/07-0170-5 ACS800-02/04/07-0210-5 ACS800-02/04/07-0260-5 ACS800-02/04/07-0320-5 ACS800-02/04/07-0400-5 ACS800-02/04/07-0440-5 ACS800-02/04/07-0490-5 ACS800-02/04/07-0550-5 ACS800-02/04/07-0610-5

165 198 198 1) 300 375 473 480 600 600 3)

132 2) 132 2) 132 2) 300 375 473 480 400 4) 400 4)

120 120 120 300 375 450 470 300 300

80 80 80 300 234 195 210 170 170

UN = 690 V (525, 575, 600, 660 and 690 V)

ACS800 type
Brake Chopper Power

Brake Resistor(s) Type SACE08RE44 SACE08RE44 SACE08RE44 SACE15RE22 SACE15RE13 SACE15RE13 SACE15RE13 SACE15RE13 SAFUR90F575 SAFUR90F575 SAFUR90F575 R [Ohm] 44 44 44 22 13 13 13 13 8 8 8 Er [kJ] 248 248 248 496 496 496 496 496 1800 1800 1800 P rcont [kW] 1 1 1 2 2 2 2 2 4.5 4.5 4.5

ACS800 type

Brake Chopper Power 5 / 60 s 10 / 60 s 30/60 s Continuous Pbr5 [kW] Pbr10 [kW] Pbr30 [kW] Pbrcont [kW] Type

Brake Resistor(s) R [Ohm] 6.00 6.00 6.00 6.00 2.70 2.70 2.70 2.00 2.00 2.00 Er [kJ] 2400 2400 2400 2400 5400 5400 5400 7200 7200 7200 P rcont [kW] 6 6 6 6 13.5 13.5 13.5 18 18 18

Continuous Pbrcont [kW] ACS800-01-0011-7 ACS800-01-0016-7 ACS800-01-0020-7 ACS800-01-0025-7 ACS800-01-0030-7 ACS800-01-0040-7 ACS800-01-0050-7 ACS800-01-0060-7 ACS800-01/07-0070-7 ACS800-01/07-0100-7 ACS800-01/07-0120-7 5.5 7.5 11 15 18.5 22 30 37 45 55 75

ACS800-04/07-0140-7 ACS800-04/07-0170-7 ACS800-04/07-0210-7 ACS800-04/07-0260-7 ACS800-04/07-0320-7 ACS800-04/07-0400-7 ACS800-04/07-0440-7 ACS800-04/07-0490-7 ACS800-04/07-0550-7 ACS800-04/07-0610-7

125 5) 125 6) 125 6) 135 7) 300 375 430 550 550 550

110 110 110 120 300 375 430 400 400 400

90 90 90 100 300 375 430 315 315 315

75 75 75 80 260 375 385 225 225 225

SAFUR80F500 SAFUR80F500 SAFUR80F500 SAFUR80F500 SAFUR200F500 SAFUR200F500 SAFUR200F500 2xSAFUR125F500 2xSAFUR125F500 2xSAFUR125F500

Maximum braking power of the ACS800 equipped with the standard chopper and the standard resistor. P br5 = 5 s/ 1 min. P br10 = 10 s/ 1 min. P br30 = 30 s/ 1 min. The drive and the chopper will withstand this braking power for 5/10/30 seconds every one minute. Note: The braking energy transmitted to the resistor during any period shorter than 400 seconds may not exceed Er . (Er varies depending on the resistor). Pbrcont = Continuous brake chopper power. The value applies to the minimum resistance value. With a higher resistance value the Pbrcont may increase in some ACS800-02/04/07 units. R = Resistance value for the listed resistor type. Note: This is also the minimum allowable resistance value for the brake resistor. Er = Energy pulse that the resistor assembly will withstand (400 s duty cycle). This energy will heat the resistor element from 40C to the maximum allowable temperature. Prcont = Continuous power (heat) dissipation of the resistor when placed correctly. Energy Er dissipates in 400 seconds.

1)

240 kW possible if Ambient below 33C 160 kW possible if Ambient below 33C 630 kW possible if Ambient below 33C 450 kW possible if Ambient below 33C 135 kW possible if Ambient below 33C 148 kW possible if Ambient below 33C 160 kW possible if Ambient below 33C

Brake Resistor SACE08RE44 SACE15RE22 SACE15RE13 SAFUR80F500 SAFUR90F575 SAFUR180F460 SAFUR125F500 SAFUR200F500 SAFUR210F575

2)

3)

4)

5)

6)

Height mm 365 365 365 600 600 1320 1320 1320 1320

Width mm 290 290 290 300 300 300 300 300 300

Depth Weight mm kg 131 6.1 131 6.1 131 6.8 345 14 345 12 345 32 345 25 345 30 345 27

7)

All brake resistors are to be installed outside the converter module. The SACE brake resistors are built in an IP 21 metal housing. The SAFUR brake resistors are built in an IP 00 metal frame.

30

3AFE 64572504 REV E EN 17.10.2003

Output filters
Factory installed and external filters.

As with all frequency converters employing the most modern IGBT inverter technology, the ACS800 output comprises - regardless of output frequency - pulses of approximately 1.35 times the mains network voltage with a very short rise time. The voltage can be almost double at the motor terminals, depending on motor cable properties.

Du/dt filtering suppresses inverter output voltage spikes and rapid voltage changes that stress motor insulation. Additionally, du/dt filtering reduces capacitive leakage currents and high frequency emission of the motor cable as well as high frequency losses and bearing currents in the motor. When to Use? The need of du/dt filtering depends on the motor insulation. For information on the

construction of the motor insulation, consult its manufacturer. If the motor does not fulfil the following requirements, the lifetime of the motor might shorten. Additionally insulated N-end (nondriven end) bearings and / or common mode filters are required to motor bearing currents with motors bigger than 100 kW. For more information see ACS800 hardware manuals.

Filter selection table for ACS800

Motor type ABB M2 and M3 motors ABB form-wound HXR and AM motors ABB random-wound HXR and AM motors Non-ABB Random-wound Nominal mains voltage (UN) UN 500 V 500 V < UN 600 V 600 V < UN 690 V 380 V < UN 690 V 380 V < UN 690 V UN 420 V 420 V < UN 500 V 500 V < UN 600 V 600 V < UN 690 V Non-ABB Form-wound 600 V < UN 690 V Motor insulation requirement Standard insulation system. Standard insulation system in conjunction with du/dt filtering or reinforced insulation. Reinforced insulation system in conjunction with du/dt filtering. Standard insulation system. Check motor insulation system with the motor manufacturer. du/dt filtering with voltages over 500 V. Insulation system must withstand LL=1300 V. If the insulation system withstands LL =1600 V and t=0.2 s, du/dt filtering is not required. With du/dt filtering, the insulation system must withstand LL=1300 V. If the insulation system withstands LL =1800 V, du/dt filtering is not required. With du/dt filtering, the insulation system must withstand LL=1600 V. If the motor insulation system withstands LL=1800 V, du/dt filtering is not required. If the motor insulation system withstands LL =2000 V and t=0.3 s, du/dt filtering is not required.

Symbol UN LL t

Explanation Nominal mains voltage. Peak line to line voltage at motor terminals. Rise time, i.e. interval during which line to line voltage at motor terminals changes from 10% to 90% of full voltage range.

3AFE 64572504 REV E EN 17.10.2003

31

External du/dt filters for ACS800-01 and ACS800-04

du/dt filter type (3 filters included in kits marked *)

Unprotected (IP 00)

Protected to IP 22

Protected to IP 54

*NOCH0120-60

*NOCH0260-60

*AOCH0260-70

ACS800
NOCH0016-60 NOCH0030-60 NOCH0070-60

*AOCH0400-70

Applicability
Factory-installed du/dt filters are available for ACS800-07/-17. They are installed inside the converter cubicle. The filters are also separately available for other ACS800 types. Then they need to be mounted externally. Unprotected (IP 00) filters must be encased.

400 V -0003-3 -0004-3 -0005-3 -0006-3 -0009-3 -0011-3

500 V

690 V

-0004-5 -0005-5 -0006-5 -0009-5 -0011-5 -0011-7 -0016-5 -0016-3 -0020-5 -0016-7 -0020-3 -0020-7 -0025-7 -0025-3 -0025-5 -0030-7 -0030-3 -0030-5 -0040-7 -0040-3 -0040-5 -0050-7 -0050-3 -0050-5 -0060-7 -0060-5 -0060-3 -0070-5 -0070-7 -0070-3 -0100-5 -0100-7 -0120-7 -0100-3 -0120-5 -0120-3 -0140-5 -0140-3 -0170-5 -0140-7 -0170-3 -0210-5 -0170-7 -0210-3 -0260-5 -0210-7 -0260-3 -0320-5 -0260-7 -0320-3 -0400-5 -0320-7 -0400-7 -0400-3 -0440-5 -0440-7 -0440-3 -0490-5 -0490-7 -0490-3 -0550-5 -0550-7 -0610-5 -0610-7

1 1 1 1 1 2

Dimensions and Weights of the du/dt filters

du/dt filter
NOCH0016-60 NOCH0016-62/65 NOCH0030-60 NOCH0030-62/65 NOCH0070-60 NOCH0070-62/65 NOCH0120-60** NOCH0120-62/65 AOCH0260-70** AOCH0400-70**

Height mm
195 323 215 348 261 433 200 765 190 190

Width mm
140 199 165 249 180 279 154 308 340 340

Depth mm
115 154 130 172 150 202 106 256 242 257

Weight kg
2.4 6 4.7 9 9.5 15.5 7 45 15.9 20.7

** 3 filters included, dimensions apply for one filter.

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3AFE 64572504 REV E EN 17.10.2003

NOCH0120-65

NOCH0016-62

NOCH0030-62

NOCH0070-62

NOCH0120-62

NOCH0016-65

NOCH0030-65

NOCH0070-65

Programming Tool
DriveAP for Adaptive Programming.

Easy to use PC tool

DriveAP is a PC tool to create, document, edit and download Adaptive Programs. Adaptive Programming can be done with the standard control panel or with DriveAP. DriveAP offers a clear and easy way to develop, test and document Adaptive Programs with a PC. DriveAP is a user-friendly tool to modify function blocks and their connections. No special programming skills are required. Basic knowledge about block programming is enough. Adaptive Programming results are easy to document as hard copies or store as PC files with DriveAP.

Upload or download
Adaptive Programs can be uploaded from connected drives and displayed graphically on a PC screen e.g. for service or documentation purposes. Ready made Adaptive Programs can be downloaded to any of the connected drives.

Features
Easy to use tool, no special skills required Create and download new programs Document your programs Upload existing programs from the drive Operating modes Stand Alone Off-Line On-Line

Three operating modes

Stand Alone Mode - DriveAP is not connected to a drive. Adaptive Programming can be carried out e.g. in the office and downloaded later on Off-Line Mode - DriveAP is connected to a drive. Adaptive Programming is carried out in batch mode On-Line Mode - DriveAP is connected to a drive. Changes to the program are written immediately to the drive and actual values are shown on the screen in real time DriveAP is part of the DriveIT folder of the IndustrialIT.

3AFE 64572504 REV E EN 17.10.2003

33

Integration Tool
DriveOPC for Windows based monitoring.

DriveOPC
DriveOPC is a software package which allows OLE for Process Control (OPC) communication between Windows applications and ABB drives. It is an ideal tool for integrating commercial PC monitoring software and ABB drives. DriveOPC can access all drives connected to the fast optical link of the drives. The number of measuring points is unlimited.

Read access to: Drive status: local, running, direction, fault, warning, homing, reference Signals and parameters Fault logger contents Event logger contents General drive information Data logger settings, status and contents Write access to: Drive Control: local, start, stop, forward, reverse, coast stop, reset fault, home, teach-in, contactoron/off, reference Parameters Fault logger clear Data logger init, start, trig, clear DriveOPC is part of the DriveIT folder of the IndustrialIT.

Features:
To control and monitor with PCbased process control software Standard interface Remote connection over LAN (local area networks) Access to Drive control Signals and parameters Data and Fault loggers

OPC based software

OPC stands for Ole for Process Control, an open architecture interface design defined by the international OPC Task Force. It is an open interface for Factory Automation.

Remote monitoring
DriveOPC enables remote connection over LAN (local area networks). The remote PC can be connected by its IP address (e.g. "164.12.43.33") or by the DNS name (e.g. "Gitas213").

34

3AFE 64572504 REV E EN 17.10.2003

Engineering Tool
DriveSize for dimensioning motors and drives.

Quality dimensioning
DriveSize is a PC program for helping the user to select an optimal motor, frequency converter and transformer, especially in those cases where a straightforward selection from a catalogue is not possible. Additionally it can be used to compute currents, network harmonics and to create documents about the dimensioning based on actual load. DriveSize contains a current version of ABB motor and frequency converter catalogues. The default values make DriveSize simple to use, but the user is provided with ample options for drive selection. The shortcut keys make drive selection easy while still honouring the relatively complicated rules. A manual selection mode is also supported. DriveSize is currently used by more than 1000 engineers globally.

DriveSize is for drive system components

3-phase standard, customized, Ex and user defined motors ABB low voltage AC drives ACS400 ACS600 ACS800 Transformers

Additional functions
The software also enables you to: Calculate the network harmonics of individual drive or set of drives Obtain efficiency values See your selections in graphical or numeric form Select manually unit from the database Print out reports Save the dimensioning results into files

DriveSize functions
The software performs dimensioning based on the following input: Speed range and mechanical load with overloads Ambient temperature and altitude Required IP-class and allowed temperature rise Supply network characteristics Load type and duty cycle Optionally current requirements for inverters DC power requirement for line supply unit Apparent power requirement for the transformer

Benefits
Select an optimal motor, frequency converter and transformer Dimensioning based on actual shaft load Documents dimensioning results, graphical and numerical presentation Network harmonic and power factor calculaton Print out and save the results

3AFE 64572504 REV E EN 17.10.2003

35

Start-up and Maintenance Tool

DriveWindow 2

WindowsTM -based, userfriendly

ABB's DriveWindow is an advanced, easy-to-use tool for the commissioning and maintenance of drive systems in different industries. Its host of features and clear, graphical presentation of the operation make it a valuable addition to your system providing information necessary for troubleshooting, maintenance and service, as well as training. DriveWindow is fully 32 bit and runs in the newer Microsoft Windows environments. DriveWindow has connection kits for both laptop and desktop PCs. With DriveWindow the user is able to follow the co-operation of two or more drives simultaneously by collecting the actual values from the drives onto a single screen or printout. Additionally, the client part of DriveWindow may reside on one Local Area Network PC, and the server side on another PC closer to the drives. This enables plant-wide monitoring to be easily accomplished with two PCs.
36
3AFE 64572504 REV E EN 17.10.2003

Powerful and versatile

DriveWindow can access all drives connected to the high speed fiber optic network Signal values can be viewed as graphs from the drive/drives A screenful of signals and parameters from the drive can be monitored and edited at one time (off-line or on-line) View data collected and stored in the drive Fault diagnosis; DriveWindow indicates the status of drives, and also reads fault history data from the drive Remote monitoring, plant wide monitoring with two PCs Back-up of drive parameters; in fault situations the file can be easily reloaded, resulting in time savings Back-up parameters or software from the drive into PC files. This version allows the entire control board content to be saved and restored later - even to empty control boards. One empty spare control card can function as a spare part for many different sizes of drives DriveWindow is part of the DriveIT folder of the IndustrialIT.

Features
Easy-to-use tool for commissioning and maintenance Several drives connected and monitored at the same time Monitor, edit or save signals and parameters, clear graphical presentation High speed communication between PC and drive Versatile back-up functions

Start-up and Maintenance Tool

DriveWindow Light 2.1

Simple to use
The DriveWindow Light 2.1 is a comprehensive commissioning and maintenance tool for ABB drives. This easy-to-use software is for editing, uploading and downloading drive parameters and, for example, monitoring the actual values and status information of the drive system. DriveWindow Light 2.1 enables most drive parameters to be set offline in the office when uploaded from the drive, and then saved in the drivespecific files. The files can be further modified and downloaded to the respective drives at the installation site.

The configuration can then be tested and fine-tuned using the software's monitoring feature. The final parameter settings can be saved for back-up purposes and also printed out easily for customer documentation. The DriveWindow Light 2.1 package consists of the software tool, based on 32-bit architecture of Microsoft Windows environment, and the RS232/RS-485 PC connection unit kit hardware. DriveWindow Light can also be used for the ACS140 and ACS400 with RS-485/232 adapter. DriveWindow Light is part of the DriveIT folder of the IndustrialIT.

Practical functions
Parameter browser for editing (online/offline) and viewing parameter values online Parameter compare function for parameters in a drive and a parameter file Parameter back-up and restore Easy adjustment of pointer type parameters, e.g. Adaptive Programming Graphical and numerical monitoring of signals Control panel with step function

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Remote Monitoring Tool

The intelligent Ethernet module NETA-01.

Browser-based, user-friendly
The intelligent Ethernet module gives simple access to the drive via the Internet communicating via a standard web browser. The user can set up a virtual monitoring room wherever there is a PC with an Internet connection or via a simple dial-up modem connection. This enables remote monitoring, configuration, diagnostics and, when needed, control. The drive can also provide process related information, such as load level, run time, energy consumption and I/O data, the bearing temperature of the driven machine, for instance.

email addresses. This opens new possibilities for the monitoring and maintenance of unmanned applications across a range of industries, for instance water, wind power, building services and oil & gas, as well as any decentralised application where the user needs access to the drives from more than one location. It also provides an opportunity for OEMs and system integrators to support their installed base globally.

The module is mounted onto a standard mounting rail inside or outside the drive unit, depending on drive type and configuration. It connects to the drive with fibre optic cables. The size of the module is 93 (h) x 35 (w) x 76.5 (d) mm. The IP address of the Ethernet module can be freely allocated. The user interface with the drive is created using embedded Java applets. The web page of the module is opened like any other web address. The home page shows a general overview of the system with traffic lights and action buttons to guide the user through the different sections.

Powerful and versatile

Up to nine drives can be connected to the intelligent Ethernet module via fibre optic links. It is available as an option for new drives, as well as an upgrade for existing systems. Ethernet allows the integration of office and process environments into a global network. The module supports the usual HTTP, IP, TCP, SMTP, BOOTP, UDP, Telnet and FTP protocols, as well as Modbus/TCP based process control. Access to the module is secured by user ID and passwords. Multiple security level enables the allocation of different access rights to normal users and administrators. Even higher levels of security can be achieved using a Virtual Private Network (VPN) connection.

No PC needed at local end

The intelligent Ethernet module has an embedded server with the necessary software for the user interface, communication and data storage. This gives ease of access, real time information and the possibility for two-way communication with the drive, enabling immediate response and actions, saving time and money. This is possible without using a PC at the local end, as required by other remote solutions.

Features
Virtual monitoring room for Monitoring Configuration of parameters Diagnostics Control, if needed Browser based access via Intra-/extra-/Internet or Simple dial-up modem connection E-mail alerts to predefined addresses No PC needed at the local end Can be used as a Modbus/TCP bridge for control purposes

E-mail alerts
The module can also send condition triggered event alerts to predefined
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Energy saving with ACS800

Environmental Product Declarations.
How much air pollution is caused by an electric motor or drive? How does the manufacture and use of electric motors and drives affect water quality? Or influence global warming? These were some of the questions ABB asked itself when it decided to assess and improve the environmental impact of its electric motors and drives. The solution was to provide Environmental Product Declarations (EPDs) for all core ABB products. EPDs describe the environmental aspects and impacts of a product line over its entire life cycle.

The EPD program aims

To enable ABB designers to assess and improve the environmental performance of a product over its full life cycle To facilitate a sound comparison of the environmental performance of alternative products, using available environmental criteria To provide ABBs customers with LCA data of ABB products to facilitate environmental assessments of their processes To promote the environmental performance of ABB products and services among its stakeholders and to enhance ABBs business The declarations are based on Life Cycle Assessment (LCA) studies and conform to ISO 14025. ABB has published three EPD brochures for the ACS800 for the 18.5, 250 and 703 kW power ratings.

flow control applications such as pumps, fans and compressors. Companies having installed AC drives have already reaped huge savings when mechanical control devices such as throttling valves, dampers or hydraulic clutches have been replaced with electronic speed control. Even more energy savings are obtainable when older AC drives are replaced by ABB AC drives. The additional energy saving can be 10% or even more. This is a result of ABB's uninterrupted product development focus on reducing losses in drive components and motors. ABBs unparalleled Direct Torque Control (DTC) technology has become a landmark in the drives industry thanks to its superior

control accuracy and frugality in power usage. The new industrial drive, the ACS800, is equipped with DTC motor control and exhibits topclass energy efficiency found in the marketplace today. It is a safe investment for a company which values high performance, reliability and low operating costs.

Energy saving tools

The software tools, PumpSave and FanSave, have been developed by ABB for predicting the energy savings. They are available for download on the web at www.abb.com/motors&drives -> AC drives -> Energy saving or email energy@fi.abb.com

AC drive efficiency vs. time (75 kW)

AC drive efficiency Motor efficiency in AC drive use Total efficiency

Reduce plant operating costs with the ACS800

One of the most tangible benefits of using AC drives has always been the saving in energy-related operating costs. AC drives save energy in many cases, first and foremost in

Efficiency, %

Year - drive technology

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ABB Oy Drives P. O. Box 184 FIN - 00381 Helsinki Finland Telephone +358 10 22 11 Telefax +358 10 222 2681 Internet http://www.abb.com/motors&drives
3AFE 64572504 REV E EN 17.10.2003 Specifications subject to change without notice. The IndustrialIT wordmark and all above-mentioned product names in the form DriveIT are registered or pending trademarks of ABB. Ad agency Piirtek #11155