Professional Documents
Culture Documents
Hardware Manual
ACS800-107 Cabinet-built Inverter Units (1.5 to 5430 kW)
List of related manuals
General manuals Code (English)
ACS800 Multidrive and Multidrive Modules Safety Instructions 3AFE64760432
ACS800 Multidrive Cabinet-installed Drives Mechanical Installation 3AFE68233402
ACS800 Multidrive and Multidrive Modules Planning the Electrical 3AFE64783742
Installation
Hardware manual
ACS800-107 Cabinet-built Inverter Units (1.5 to 5430 kW) Hardware 3AFE68233453
Manual
You can find manuals and other product documents in PDF format on the Internet. See section
Document library on the Internet on the inside of the back cover. For manuals not available in the
Document library, contact your local ABB representative.
ACS800-107 Cabinet-built Inverter Units
1.5 to 5340 kW
Hardware Manual
3AFE68233453 REV D
EN
EFFECTIVE: 2013-02-14
Table of contents
Table of contents
Hardware description
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Typical drive system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Inverter unit hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cabinet system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inverter module frames R2i to R5i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Module layout (Frame size R3i pictured) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Inverter module frame R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Module layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Motor cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Frame R8i and multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Redundancy (Reduced run capability) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Control electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Motor cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
The RDCU Drive Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
The RAPI-01C Auxiliary Power Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
The CDP 312R Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Type code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Basic code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Option codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Table of contents
6
Table of contents
7
Relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
DDCS fibre optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
24 VDC power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Installation checklist
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Start-up
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Checks with no voltage connected. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Connecting voltage to auxiliary circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Checks with auxiliary voltage connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Connecting voltage to inverter unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Checks with voltage connected to inverter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Control from an overriding system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Disconnecting/Reconnecting an inverter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Maintenance
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Redundancy (Reduced run capability) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Checking and replacing the air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Heatsinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Fan replacement (R2i, R3i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Additional fan replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Fan replacement (R4i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Additional fan replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Fan replacement (R5i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Additional fan replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Fan replacement (R7i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Fan replacement (R8i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
IP54 (UL type 12) fan replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
PPCS branching unit (APBU-xx) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Memory backup battery replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Power connections (R8i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Table of contents
8
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Capacitor reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
DC fuse replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Fault tracing
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
LEDs of the drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Technical data
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Ratings, inverter modules used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
DC capacitance, DC fuses, noise, cooling characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Input power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Motor connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Circuit diagrams
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
R2i/R3i inverter modules Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
R2i/R3i inverter modules - Block diagram (Safe torque off, +Q967) . . . . . . . . . . . . . . . . . . . . . . . . 97
R4i inverter module Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
R4i inverter module - Block diagram (Safe torque off, +Q967) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
R5i inverter module Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
R5i inverter module - Block diagram (Safe torque off, +Q967) . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
R7i inverter module Internal diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
R7i inverter module - Internal diagram (Safe torque off, +Q967) . . . . . . . . . . . . . . . . . . . . . . . . . 104
R8i inverter module Internal diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
R8i inverter module - Internal diagram (Safe torque off, +Q967) . . . . . . . . . . . . . . . . . . . . . . . . . 106
R8i inverter module Charging circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
2R8i inverter unit Charging circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3R8i inverter unit Charging circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
R8i inverter unit I/O and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
R8i inverter unit - I/O and control (Safe torque off, +Q967). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2R8i inverter unit I/O and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2R8i inverter unit - I/O and control (Safe torque off, +Q967) . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Example - Emergency stop (Category 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Example Prevention of unexpected start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Table of contents
9
Example - Safe torque off with a safety relay (+Q968), frames R2i-R4i . . . . . . . . . . . . . . . . . . . . 117
Example - Safe torque off with a safety relay (+Q968), frame R5i. . . . . . . . . . . . . . . . . . . . . . . . . 118
Example - Safe torque off with a safety relay (+Q968), frame R7i. . . . . . . . . . . . . . . . . . . . . . . . . 119
Example - Safe torque off with a safety relay (+Q968), frame R8i. . . . . . . . . . . . . . . . . . . . . . . . . 120
Dimensions
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
General cabinet dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Common motor terminal cubicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Further information
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Table of contents
10
Table of contents
11
Compatibility
The manual is compatible with ACS800 multidrive inverter units that form a part of an
ACS800 multidrive system. ACS800 multidrive inverter units have the basic type
designation of ACS800-107.
Safety instructions
Follow all safety instructions delivered with the drive.
Read the complete safety instructions before you install, commission, or use
the drive. The complete safety instructions are given in the document ACS800
Multidrive and Multidrive Modules Safety Instructions (3AFE64760432 [English]).
Read task specific safety instructions before starting the task. See the section
describing the task.
Reader
The reader of the manual is expected to know the standard electrical wiring
practices, electronic components, and electrical schematic symbols.
Contents
The chapters of this manual are briefly described below.
Introduction to this manual introduces this manual.
Hardware description describes the main parts of the drive.
Electrical installation describes the cabling and wiring of the drive.
Motor control and I/O board (RMIO) shows the control board specifications.
External +24 V power supply for the RMIO board describes how to connect
external +24 V power supply for the RMIO board.
Installation checklist helps in checking the mechanical and electrical installation of
the drive.
Start-up guides through the drive start-up procedure.
Maintenance contains maintenance instructions of the drive.
Fault tracing lists the LEDs of the drive.
Technical data contains the technical specifications of the drive, e.g. ratings,
frame sizes and technical requirements and provisions for fulfilling the
requirements for CE and other markings.
Circuit diagrams contains circuit diagram examples.
Dimensions contains information on the dimensions of the drive.
AGPS An optional board within inverter modules used to implement the Prevention of
unexpected start-up function.
ASTO An optional board within inverter modules used to implement the Safe torque off
function (option +Q967 or +Q968).
DSU Diode supply unit (consisting of one or more diode supply modules).
Frame (size) Relates to the construction type of the component in question. For example,
several supply modules with different nominal powers may have the same basic
construction. The term is often used in reference to a group of components that
share a similar mechanical construction.
To determine the frame size of a component, refer to the rating tables in chapter
Technical data.
Inverter unit An entity containing all inverter modules controlling a motor, together with their
control electronics, and I/O and auxiliary components.
I/O Input/Output
Term/ Explanation
Abbreviation
NDBU or Types of optical branching unit for fibre links that use the DDCS protocol.
ADBU
NGPS or Gate driver Power Supply board. An optional board within inverter modules used to
AGPS implement the Prevention of unexpected start-up function.
NPBU or Types of optical branching unit used for connecting parallel-connected inverter
APBU modules to the RDCU.
PPCS Power Plate Communication System; a protocol used in the optical fibre link that
controls the output semiconductors of an inverter module.
RDCO DDCS Communication Option. A satellite board that can be snapped onto the
RMIO board to increase the number of fibre optic channels available.
RDCU Drive control unit. The RDCU is a separate unit consisting of an RMIO board built
in a plastic housing. Module sizes R2i to R5i have the RMIO board built-in.
Hardware description
M
2 5 5 6
M M M
M M
3~ 3~
1
1 Input (AC) fuses
2 Supply unit (in this example, consisting of two supply modules)
3 DC bus
4 Inverter DC fuses or switch fuses
5 Inverter units (in this example, one of the units consists of two
inverter modules connected in parallel)
6 Brake chopper(s) (optional)
Hardware description
16
General
An inverter unit contains the components required to control one motor. These
include one or more inverter modules connected in parallel, together with the
necessary auxiliary equipment such as control electronics, fusing, cabling and
switchgear.
The ACS800-107 inverter units range from 1.5 to 5340 kW in power. The ACS800-
107 inverter units employ inverter modules from frame size R2i to R8i. Up to
approximately 500 kW, inverter units consist of one module only; higher powers are
achieved by connecting multiple R8i modules in parallel.
All inverter modules used in the ACS800-107 units have coated circuit boards as
standard.
Cabinet system
The inverter units are built in adjoining cubicles. Examples of the cabinet
configurations are included below as well as in chapter Dimensions. The motor
cabling direction is optionally up or down see below under each module frame size
for specific information.
Section Control interfaces below shows the available control and I/O options of the
inverter unit.
Cooling
Each inverter module has its own cooling fan(s). Control cubicles may have
additional cooling fans.
The inverter cubicles have the air intake at the lower part of the door, while the air
outlets are on the roof. The intake can optionally be through the floor, adding
130 mm (5.12) to the standard depth of 600 mm (23.62) of the cabinet.
Hardware description
17
Item Explanation
2 DC (input) connections
4
3 Motor (output) connection
2 3
Hardware description
18
Cabinet layout
Several inverter modules of frame size R2i to R5i may be installed in one cubicle.
Each module is equipped with dedicated DC fuses or switch fuse. The modules have
an internal capacitor bank charging circuit.
The modules are mounted in a slightly inclined position. The picture below presents
an example of a cubicle with one R3i and one R5i module.
DC input cable
DC input cable
Hardware description
19
1
1
Item Explanation
1 DC (input) connections.
6 2 Cooling fan.
6 3 Output busbars. By default,
these busbars are extended
to the front part of the cubicle.
4
3
Motor cabling
The motor cables are connected to the output busbars at the bottom of the cubicle.
For top exit, the depth of the cabinet is increased by 130 mm (5.12 in.).
Hardware description
20
1
3
5
2
Item Explanation
1 DC (input) connections
2 Output busbars. Match the quick connector socket mounted in the cubicle
3 Fibre optic connectors of the AINT board. Connected to the RDCU drive control unit (via
an APBU branching unit in case of parallel inverter modules)
5 Handle
6 Cooling fan
Hardware description
21
Hardware description
22
Cabinet layout
Several inverter modules may be installed in one cubicle. Each module is equipped
with dedicated DC fuses; a switch fuse is optional. When modules equipped with a
switch fuse are powered, a charging circuit automatically charges the capacitor
banks of the modules before the main contacts of the switch fuse close.
The picture below presents an example of a cubicle with two R8i inverter modules.
Inverter modules
Motor cabling
The motor cable is connected to the module via a quick connector at the back of the
module. With a common motor terminal cubicle (optional), the outputs of the parallel-
connected inverter modules are run to a separate cubicle containing a single set of
output busbars. The cubicle is available in bottom-exit and top-exit variants.
If a common motor terminal cubicle (optional) is not present, each inverter module
must be extracted from the cabinet for motor cabling and then re-inserted. In this
case, each inverter module is to be cabled individually to the motor. The standard
cabling direction is down; top exit adds 130 mm (5.12 in.) to the depth of the cubicle.
Hardware description
23
Control interfaces
The following diagram shows the control interfaces and I/O options of an inverter
unit.
Hardware description
24
Hardware description
25
Type code
Each inverter unit has a type designation label. (Note that multiple small inverter
units can be installed within one cubicle.) The type code on the label contains
information on the specifications and configuration of the unit.
The first 17 digits form the basic code. It describes the basic construction of the
unit. The fields in the basic code are separated with hyphens.
The option codes follow the basic code. Each option code starts with an
identifying letter (common for the whole product series), followed by descriptive
digits. The option codes are separated by plus signs.
The main selections are described below. Not all options are necessarily available
for all types. For more information, contact your local ABB representative.
Basic code
Digit no. Name/Description Alternatives Description
5 380/400/415/440/460/480/500 V. Nominal
voltage: 500 V.
Option codes
Identification Name/Description Alternatives Description
Hardware description
26
Hardware description
27
Electrical installation
WARNING! Make sure that the drive system is disconnected from the mains (input
power) during installation. If the drive system is already connected to the mains, wait
for 5 min after disconnecting mains power.
Inverter unit
Do not make any voltage tolerance or insulation resistance tests on any part of the
inverter unit as testing can damage the inverter unit. Every inverter unit has been
tested for insulation between the main circuit and the chassis at the factory. Also,
there are voltage-limiting circuits inside the inverter unit which cut down the testing
voltage automatically.
U1
M
V1
3~
ohm W1
PE
Electrical installation
28
Diagram
Inverter module
OUTPUT
U2 V2 W2
1)
2)
U1 V1 W1
3~
Motor
1) 360 degrees grounding Grounding of the motor cable shield at the motor end
For minimum radio frequency interference:
ground the cable shield 360 degrees at the lead-through of
the motor terminal box
Electrical installation
29
Electrical installation
30
Motor cable
clamp
Electrical installation
31
Diagram
Inverter module
OUTPUT
U2 V2 W2
U2 V2 W2
Cabinet PE
*)
U1 V1 W1
3~
Motor
*Use a separate grounding cable if the conductivity Grounding of the motor cable shield at the motor end
of the cable shield is less than 50% of the For minimum radio frequency interference:
conductivity of the phase conductor in a cable with
ground the cable shield 360 degrees at the lead-through of
no symmetrically constructed grounding conductor
the motor terminal box
(see document ACS800 Multidrive and Multidrive
Modules Planning the Electrical Installation
[3AFE64783742], English).
Note: 360 degrees grounding
If there is a symmetrically constructed grounding
conductor in the motor cable in addition to the
conductive shield, connect the grounding conductor Conductive gaskets
to the grounding terminal at the drive and motor
ends. or ground the cable by twisting the shield as follows:
flattened width > 1/5 length.
Do not use an asymmetrically constructed motor
cable. Connecting its fourth conductor at the motor
end increases bearing currents and causes extra
wear. b > 1/5 a
b
a
Electrical installation
32
Electrical installation
33
PE
U2
V2
W2
U1
V1
M
W1 3~
U2 PE
V2
W2
PE
U2
V2
U1
V1
M
W2
W1 3~
PE
U2
V2
W2
Electrical installation
34
PE
U2
V2
W2
U2
V2
U1
V1
M
W2
W1 3~
PE
U2
V2
W2
PE
U2
V2
U1
V1
M
W2
W1 3~
PE
U2
V2
W2
The recommended cable types are given in the document ACS800 Multidrive and
Multidrive Modules Planning the Electrical Installation (3AFE64783742 [English]).
Electrical installation
35
Without the optional interconnection, each module is cabled individually to the motor.
Jumpering the output cables from one inverter module to another (and then to the
motor) is allowed only if the modules are equipped with internal du/dt filters. See the
cabling examples below.
PE
U2
V2
W2
U1
V1
M
W1 3~
U2 PE
V2
W2
PE
U2
V2
U1
V1
M
W2
W1 3~
PE
U2
V2
Note: Allowed only if modules
W2 equipped with internal du/dt
filters (+E205).
PE
U2
V2
W2
U1
V1
M
W1 3~
U2 PE
V2
W2
The recommended cable types are given in the document ACS800 Multidrive and
Multidrive Modules Planning the Electrical Installation (3AFE64783742 [English]).
Electrical installation
36
Connection procedure
WARNING! The inverter modules are heavy and have a high centre of gravity. Be careful when
manoeuvring the modules. In order to minimise the danger of toppling over, keep the support legs
of the modules extended whenever manoeuvring the modules outside the cabinet. Follow the
safety instructions given in ACS800 Multidrive and Multidrive Modules Safety Instructions (3AFE64760432
[English]).
6a
4
3
8
9a 9b
6c
6b
Electrical installation
37
Lead the cables into the cabinet below each inverter module. Make the 360 grounding arrangement at the
cable entry as shown.
Grommet (in
IP54 units only)
Twist the cable screens into bundles and connect to cabinet PE (ground) busbar.
At the motor, connect the cables according to instructions from the motor manufacturer. Pay special
attention to the phase order.
Electrical installation
38
PE
U2
V2
U1
V1
M
W2
W1 3~
PE
The recommended cable types are given in the document ACS800 Multidrive and
Multidrive Modules Planning the Electrical Installation (3AFE64783742 [English]).
Electrical installation
39
Connection procedure
Lead the cables into the output cabinet. Make the 360 grounding arrangement at the cable entry as
shown.
Grommet (in
IP54 units only)
Twist the cable screens into bundles and connect to cabinet PE (ground) busbar.
At the motor, connect the cables according to instructions from the motor manufacturer. Pay special
attention to the phase order.
Electrical installation
40
DDCS communication
option module 3:
RDCO
Install shroud
(included) on the relay
4
3
terminals exceeds
50 V AC
Electrical installation
41
Frame R5i
Optional module 1
Optional module 2
RMIO X39 for
control panel cable
DDCS communication option
module 3: RDCO
Electrical installation
42
24 V DC power input
LED indicators
DDCS
communication option
module 3: RDCO
Connection procedure
Turn the supply (rectifier) unit switch-disconnector into open position.
Release the door handle and open the door of the inverter cubicle.
Remove shrouding wherever necessary to access the cable entries and trunking. Run the cables into the
inside of the cabinet through the grommets provided.
Top entry units only: If several cables need to be run through one grommet, use Loctite 5221 (cat. no.
25551) under the grommet to seal the cable entry.
Electrical installation
43
Side view
Strain relief EMI conductive
cushions
If the outer surface of a cable shield is non-conductive, turn the shield inside out as shown below and
apply copper foil to keep the shielding continuous. Do not cut the grounding wire (if present).
Copper foil
Grounding wire
On top entry units, sort the cables so that the thinnest and thickest cables are at opposite ends of the
opening.
Top view
Run the cables to the RDCU control unit (or other connection point) using the existing cable trunking
wherever possible.
Cut the cables to suitable length. Strip the cables and conductors.
Twist the cable shields into bundles and connect them to the ground terminal nearest to the terminal block.
(There is a grounding busbar next to the RDCU unit.) Keep the unshielded portion of the cables as short
as possible.
Connect the conductors to appropriate terminals (see chapter Motor control and I/O board (RMIO) and the
circuit diagrams delivered with the unit).
Electrical installation
44
24 V DC power input
LED indicators
DDCS
communication option
module 3: RDCO
Electrical installation
45
Connection procedure
Turn the supply (rectifier) unit switch-disconnector into open position.
Release the door handle and open the door of the control cubicle.
Run the cables into the inside of the cubicle through the grommets provided.
Top entry units only: If several cables need to be run through one grommet, use Loctite 5221 (cat. no.
25551) under the grommet to seal the cable entry.
Side view
Strain relief EMI conductive
cushions
If the outer surface of a cable shield is non-conductive, turn the shield inside out as shown below and
apply copper foil to keep the shielding continuous. Do not cut the grounding wire (if present).
Copper foil
Grounding wire
On top entry units, sort the cables so that the thinnest and thickest cables are at opposite ends of the
opening.
Top view
Run each cable to the appropriate terminal block. Wherever possible, use the existing cable trunking in the
cabinet. Use sleeving wherever the cables are laid against sharp edges.
Cut the cables to suitable length. Strip the cables and conductors.
Electrical installation
46
If connecting to the RDCU drive control unit: Remove the outer insulation of the cables where they pass
through the strain relief/grounding clamp below the RDCU. After running all the necessary control cables
through the clamp, tighten it.
Note: If the outer surface of a cable shield is non-conductive, turn the shield inside out as shown below
and apply copper foil to keep the shielding continuous. Do not cut the grounding wire (if present).
Copper foil
Grounding wire
If NOT connecting to the RDCU drive control unit: Twist the cable shields into bundles and connect them to
the ground terminal nearest to the terminal block. Keep the unshielded portion of the cables as short as
possible.
Connect the conductors to appropriate terminals (see chapter Motor control and I/O board (RMIO) and the
circuit diagrams delivered with the unit).
Electrical installation
47
4
3
2
1
Electrical installation
48
WARNING! Read and follow the safety instructions, given in ACS800 Multidrive and
Multidrive Modules Safety Instructions (3AFE64760432 [English]). Ignoring the
instructions can cause physical injury or death, or damage to the equipment.
PC connection
Connect the PC to CH3 of the RDCO module via a fibre optic link. The RDCO is
attached to an option slot of the RMIO board. See also Fibre optic links below.
Electrical installation
49
Module
Keep as short as
possible
Shield
4
3
2
1
Keep as short as
possible
Electrical installation
50
Electrical installation
51
Analogue outputs
Two programmable current outputs: 0 (4) to 20 mA, RL < 700 ohm
Resolution 0.1% (10 bit)
Inaccuracy 1% (Full Scale Range) at 25 C (77 F). Temperature coefficient: 200 ppm/C
( 111 ppm/F) max.
Digital inputs
Six programmable digital inputs (common ground: 24 VDC, -15% to +20%) and a start
interlock input. Group isolated, can be divided in two isolated groups (see Isolation
and grounding diagram below).
Thermistor input: 5 mA, < 1.5 kohm 1 (normal temperature), > 4 kohm 0
(high temperature), open circuit 0 (high temperature).
Internal supply for digital inputs (+24 VDC): short circuit proof. An external 24 VDC
supply can be used instead of the internal supply.
Isolation test voltage 500 VAC, 1 min
Logical thresholds < 8 VDC 0, > 12 VDC 1
Input current DI1 to DI 5: 10 mA, DI6: 5 mA
Filtering time constant 1 ms
Relay outputs
Three programmable relay outputs
Switching capacity 8 A at 24 VDC or 250 VAC, 0.4 A at 120 VDC
Minimum continuous current 5 mA rms at 24 VDC
Maximum continuous current 2 A rms
Isolation test voltage 4 kVAC, 1 minute
The terminals on the RMIO board as well as on the optional modules attachable to the board fulfil the Protective Extra
Low Voltage (PELV) requirements stated in EN 50178 provided that the external circuits connected to the terminals also
fulfil the requirements.
9 AO1+
10 AO1-
11 AO2+
12 AO2-
X22
1 DI1
2 DI2
3 DI3
4 DI4
Jumper J1 settings:
9 DGND1
When to use
External +24 V power supply for the RMIO board is recommended if
the application requires fast start after connecting the input power supply
fieldbus communication is required when the input power supply is disconnected.
For current consumption of the RMIO board, see chapter Motor control and I/O
board (RMIO).
Parameter settings
In Standard Control Program, set parameter 16.9 CTRL BOARD SUPPLY to
EXTERNAL 24V if the RMIO board is powered from an external supply.
4
4
3
6 7
5
Installation checklist
Checklist
Check the mechanical and electrical installation of the drive before start-up. Go
through the checklist below together with another person.
Check that
MECHANICAL INSTALLATION
There is sufficient free space around the unit. (See chapter Technical data.)
The ambient operating conditions are allowed. (See chapter Technical data.)
The unit is properly fastened to the floor. (See separate document ACS800 Multidrive
Cabinet-installed Drives Mechanical Installation [3AFE68233402, English])
The cooling air is able to flow freely.
The motor and the driven equipment are ready for start. (See section Technical data: Motor
connection, and separate document ACS800 Multidrive and Multidrive Modules Planning the
Electrical Installation [3AFE64783742, English])
ELECTRICAL INSTALLATION (See chapter Electrical installation, and separate document
Converter modules with electrolytic DC capacitors in the DC link, Capacitor reforming instructions
(3BFE64059629 [English])
The capacitors are reformed if stored over one year, refer to Converter modules with
electrolytic DC capacitors in the DC link, Capacitor reforming instructions (3BFE64059629
[English]).
The drive is grounded properly.
The input voltage matches the nominal input voltage of the inverter unit.
The power connections at UDC+ and UDC and their tightening torques are OK.
Appropriate DC fuses are installed.
The motor is of the correct voltage.
The star/delta connection in the motor terminal box is correct.
The motor connections at U2, V2 and W2 and their tightening torques are OK.
The motor cable is routed away from other cables.
Installation checklist
62
Check that
There are no power factor compensation capacitors in the motor cable.
The external control connections to the inverter unit are OK (including emergency stop and
Prevention of unexpected start-up wiring).
The Safe torque off (+Q967 or +Q968) circuit is completed and the supply voltage for
ASTO board is 24 V.
There are no tools, foreign objects or dust from drilling inside the modules or the cabinet.
All shrouds and covers are in place.
Installation checklist
63
Start-up
WARNING! The work described in this chapter must only be carried out by a
qualified electrician. The directions given in the document ACS800 Multidrive and
Multidrive Modules Safety Instructions (3AFE64760432 [English]) must be followed.
Neglecting the safety instructions can cause injury or death.
Installation checklist
The installation of the drive system must be checked before commissioning the drive
unit(s).
Check that
The mechanical and electrical installation of the drive system has been inspected and
approved. (See Installation checklist.)
The insulation resistance of the assembly has been checked according to instructions. (See
Electrical installation.)
Start-up
64
Action Information
WARNING! Ensure that the disconnector of the supply transformer is locked out,
i.e. no voltage is, or can be, connected to the drive system inadvertently. Check
also by measuring that no voltage is actually connected.
If the motor has a safety switch, make sure it is open. If the motor has no safety
switch, open the Prevention of unexpected start-up circuit (if present).
1. Drive data
Find out the following data for each drive unit and note
down any deviations from delivery documents.
Motor, pulse encoder and cooling fan rating plate data
correspond to the values in the motor list.
Motor temperature method: Pt100, PTC, other?
Motor fan of separately ventilated motors. Check the
current, the overcurrent protection setting and the
functioning of the fan output control circuit.
Direction of motor rotation.
Maximum and minimum speeds, fixed speeds.
Speed scaling factor, gear ratio, roll diameter, etc.
Acceleration and deceleration times.
Inertia compensation.
Operating modes (stop mode, etc.).
2. Voltage to cooling fans
Check that any circuit breakers and protection switches in See the circuit diagrams
the cooling fan supply circuit are closed. delivered with the drive.
3. APBU memory backup (units with parallel-connected inverter modules only)
Locate the PPCS branching unit (APBU-xx). Enable By default, memory backup is
memory backup battery by setting actuator 6 of switch S3 switched off to save the battery.
to ON.
4. Safety features
If the motor has a safety switch, make sure it is open. If the See the circuit diagrams
motor has no safety switch, open the Prevention of delivered with the drive.
unexpected start-up (+Q950 or +Q957) circuit or the Safe
torque off (+Q967 or +Q968) circuit, if present.
Start-up
65
Action Information
WARNING! Make sure it is safe to connect voltage to the input terminals. Ensure
that while the voltage is connected
nobody is working on the unit or circuits that are wired from outside circuits to the
drive system
the cabinet doors are closed.
Disconnect any auxiliary voltage (230 or 115 V AC) cables
that lead from the terminal blocks to the outside of the
equipment and have not yet been checked. Also disconnect
any uncompleted wiring.
Disconnect the communication link between the drive Refer to the circuit diagrams
system and any overriding system. delivered with the drive.
Make sure the main contactor/air circuit breaker cannot be
switched on inadvertently by remote control.
Be ready to trip the main breaker of the supply transformer
in case something abnormal occurs.
Ensure all cabinet doors are closed.
Close the main breaker of the supply transformer. The input terminals of the drive
system are now energised.
Close the auxiliary voltage switch (F10). The auxiliary voltage circuit is
now energised.
Start-up
66
Action Information
WARNING! This section includes instructions for checking/measuring circuits under
voltage. Only a qualified person is allowed to carry out the work. Appropriate and
approved measuring instruments must be used. Follow the safety instructions given
in ACS800 Multidrive and Multidrive Modules Safety Instructions (3AFE64760432
[English]).
Ensure the actions described in the previous section
(Connecting voltage to auxiliary circuits) have been
completed.
1. Cooling fans
Check that the cooling fans rotate freely in the right A paper sheet set on the lower
direction, and the air flows upwards. gratings stays. The fans run
Notes: noiselessly.
The cooling fan(s) of frame R2i to R5i, as well as R8i Note: With frame R8i inverter
inverter modules equipped with the +C126 option modules, it must be visually
(speed-controlled fan), will not rotate until the DC checked that the fan rotates in
voltage to the module is connected. the direction indicated by an
arrow on the fan housing.
Depending on the wiring, it may be necessary to have
the supply unit powered before the fans can be started.
In this case, check the cooling fans after powering the
supply unit.
2. Parameters
Set the drive parameters for each inverter unit. See the appropriate Firmware
Manual.
Start-up
67
Action Information
WARNING! When connecting voltage to the supply unit, the DC busbars will
become live, as will all the inverters connected to the DC busbars.
Make sure it is safe to connect voltage to the supply unit. Ensure that
nobody is working on the unit or circuits that are wired from outside circuits to the
drive system
it is safe to start the motor
the cabinet doors are closed.
WARNING!
Inverter units with a DC switch/disconnector (switch fuse):
When the DC switch fuse and the main breaker/contactor of the supply unit are
closed, the inverter unit is energised through the charging circuit even though the
DC fuses of the inverter unit (i.e. the fuses in the switch fuse) are removed. When
the DC switch fuse is open, the fuses in it can be removed and re-inserted.
Inverter units without a DC switch/disconnector (switch fuse):
If the inverter unit only has DC fuses without a switch fuse, all the inverter units with
the DC fuses in place will be energised when the main breaker/contactor closes. To
prevent this, remove the fuses from the inverter units which are to remain
unenergised before connecting voltage. When the main breaker/contactor of the
supply unit is closed (DC busbars are live), never remove or insert the DC
fuses of an inverter unit.
INVERTER UNITS EQUIPPED WITH DC SWITCH/DISCONNECTOR
Turn the DC switch/disconnector into ON position. As soon as the DC bus is
energised later on in this
procedure, the capacitor bank of
the inverter module is charged
automatically.
POWERING THE DC BUS
WARNING! Before closing the main contactor/air circuit breaker, make sure that a
sufficient inverter power is connected to the intermediate (DC) bus. As rules of
thumb,
the sum power of the inverters connected must be at least 30% of the sum
power of all inverters
the sum power of the inverters connected must be at least 30% of the rated
power of the brake unit (Pbr.max) (if present).
If the above-mentioned rules are not followed, the DC fuses of the connected
inverter units may blow, or the brake chopper (if present) may be damaged.
Start-up
68
Ensure that the number of inverters connected to the DC See the WARNING above.
bus is sufficient.
Close the main contactor (or air circuit breaker) of the The DC bus is now powered,
supply unit. along with all inverters that are
connected to it.
Action Information
Check the rotation direction of the motor.
Check the operation of the pulse encoder (if present). Refer to the user manual of the
pulse encoder interface module.
Check the functioning of the emergency stop function (if Refer to the circuit diagrams
present) from each operating location. See document delivered with the drive system
Safety options for ACS800 cabinet-installed drives (+Q950,
+Q951, +Q952, +Q963, +Q964, +Q967 and +Q968),
Wiring, start-up and operation instructions
(3AUA0000026238 [English]).
Check that the Prevention of unexpected start-up function
(if present) works. See document Safety options for
ACS800 cabinet-installed drives (+Q950, +Q951, +Q952,
+Q963, +Q964, +Q967 and +Q968), Wiring, start-up and
operation instructions (3AUA0000026238 [English]).
Check that the Safe torque off function (if present) works.
See document Safety options for ACS800 cabinet-installed
drives (+Q950, +Q951, +Q952, +Q963, +Q964, +Q967 and
+Q968), Wiring, start-up and operation instructions
(3AUA0000026238 [English]).
Start-up
69
Action Information
1. Disconnect all voltages from the drive system.
2. Connect the communication link between the overriding Refer to the circuit diagrams
system and the inverter. delivered with the drive system.
3. Power up the drive system.
4. Check
the start/stop functions
torque etc. references
alarm/fault words
function in case of a communication break
updating intervals of the control program
other relevant points of the application.
Action Information
1. Disconnecting an inverter unit
1. Stop the inverter using a stop command and wait until the
motor has stopped completely.
2. Open the Prevention of unexpected start-up circuit (if
present) or the Safe torque off circuit (if present).
3. Open the DC switch/disconnector (switch fuse) of the
inverter unit.
2. Reconnecting an inverter unit
1. Close the DC switch/disconnector (switch fuse) of the The capacitor banks of the
inverter unit. inverter modules are charged
automatically.
2. Close the Prevention of unexpected start-up circuit (if The inverter unit is ready for
present) or the Safe torque off circuit (if present). operation.
Start-up
70
Start-up
71
Maintenance
Safety instructions
Only a qualified electrician is allowed to perform the maintenance.
Before starting work on the drive system,
isolate the drive system from the main supply
open the switch-disconnectors and lock them out in the open position
switch off any voltages connected to the I/O terminals
wait for 5 minutes to let the intermediate circuit capacitors discharge
ensure there is no dangerous voltage present by measuring the voltage on the
input, I/O and intermediate circuit (DC bus) terminals.
Maintenance
72
Maintenance intervals
This table lists the routine maintenance intervals recommended by ABB.
Consult your local ABB Service representative for more details on the maintenance.
On the Internet, go to http://www.abb.com/drivesservices.
Maintenance
73
4. Units with DC switch fuses only: Locate the ASFC switch fuse controller and set
the fibre optic link to the absent module to disabled using the appropriate switch
(S1, S2 or S3).
D IS
D IS
D IS
P W R
U D C
U D C
U D C
E S O N L Y .
E N
E N
E N
1 1 5 V
V O L T A G E
V 5
V 6
V 3
V 4
V 1
V 2
E D W IT H
S W IT C H F U S E C O N T R O L L E R
R A T E D
V A C
V A C
IN V 1
IN V 2
IN V 3
S 1
S 2
S 3
B E U S
B D R IV
X IM U M
: 6 9 0
6 0 0
S T A T
S T A T
S T A T
S T E M
X 8
6 4 7 3 9 6 1 1
2 3 0 V
:
IE C
M A
U L
A B
S Y
T O
S U P P L Y V O L T A G E (X 5 )
E X C IT A T IO N V O L T A G E
O P E R . T E M P E R A T U R E
2 3 0 V , 5 0 /6 0 H z , 4 0 m A
1 1 5 V , 5 0 /6 0 H z , 8 0 m A
C H A R G IN G C U R R E N T
S O L E N O ID C O N T R O L
M O N IT O R IN G IN P U T S
(X 1 - X 3 ) M A X 1 6 A D C
O U T P U T (X 5 ) 1 1 5 /2 3 0
V A C , M A X 2 A / 3 ,5 s
1 5 V D C , M A X 1 0 m A
A S F C -0 1 C
A U X 2
N S O L
L S O L
IR 1 +
IR 1 -
IR 2 +
IR 2 -
IR 3 +
IR 3 -
X 7
IN V 1
IN V 2
IN V 3
G N D
G N D
1 5 V
P E
R A T IN G S
O U T P U T (X 4 )
L
N
M A X + 7 0 C
3
1
2
3
4
5
6
1
2
3
1
2
3
1
2
3
1
2
X 2
X 5
X 1
X 3
X 4
F 1
B A R C O D E L A B E L
5. Make the necessary parameter adjustments in the drive firmware. Refer to the
appropriate Firmware Manual.
Reconnect the module after service in reverse order.
Heatsinks
Heatsink fins pick up dust from the cooling air. Inverter modules run into
overtemperature warnings and faults if the heatsink is not clean. In a normal
environment (not dusty, not clean) the heatsink should be checked annually, in a
dusty environment more often.
Clean the heatsink as follows (when necessary):
1. Remove the cooling fan as described in Cooling fans elsewhere in this chapter.
2. Blow clean, dry compressed air from bottom to top and simultaneously use a
vacuum cleaner at the air outlet to trap the dust. Note: Prevent the dust from
entering adjoining equipment.
3. Refit the cooling fan.
Maintenance
74
Cooling fans
The lifespan of the cooling fan depends on the drive usage and ambient
temperature. See the appropriate Firmware Manual for the actual signal which
indicates the hours of usage of the fan.
Fan failure can be predicted by the increasing noise from fan bearings and the
gradual rise in the heatsink temperature in spite of heatsink cleaning. If the drive is
operated in a critical part of a process, fan replacement is recommended once these
symptoms start appearing. Replacement fans are available from ABB. Do not use
other than ABB-specified spare parts.
Bottom view
1
2
Maintenance
75
2 2
1 1 4 4
4 4
Bottom view
Maintenance
76
Maintenance
77
Maintenance
78
2 2 4
1
3
2
2
3
7
6
5
5
10
9
8
8
9
8 8
12
11 11
Maintenance
79
3 4 5
Maintenance
80
Capacitors
The drive intermediate circuit employs several electrolytic capacitors. Their lifespan
depends on drive loading and ambient temperature. Capacitor life can be prolonged
by lowering the ambient temperature.
It is not possible to predict a capacitor failure. Capacitor failure is usually followed by
a mains fuse failure or a fault trip. Contact ABB if capacitor failure is suspected.
Replacements are available from ABB. Do not use other than ABB-specified spare
parts.
Capacitor reforming
Reform (re-age) spare part capacitors once a year according to Converter modules
with electrolytic DC capacitors in the DC link, Capacitor reforming instructions
(3BFE64059629 [English]).
Fuses
DC fuse replacement
For suitable fuse types, see the table on page 86.
Maintenance
81
Fault tracing
Fault tracing
82
Fault tracing
83
Technical data
Technical data
84
Technical data
85
Symbols
Nominal ratings
Icont.max Continuous RMS output current. No overloadability at 40 C (104 F).
Imax Maximum output current. Allowable for 10 seconds at start, otherwise as long as allowed
by drive temperature. Note: Maximum motor shaft power is 150% Phd.
Typical ratings for no-overload use
Pcont.max Typical motor power. The power ratings apply to most IEC 60034 motors at nominal voltage
(400, 500 or 690 V).
Typical ratings for light-overload use (10% overloadability)
I2N Continuous rms current. 10% overload is allowed for 1 minute every 5 minutes.
PN Typical motor power. The power ratings apply to most IEC 60034 motors at nominal voltage
(400, 500 or 690 V).
Typical ratings for heavy-duty use (50% overloadability)
I2hd Continuous rms current. 50% overload is allowed for 1 minute every 5 minutes.
Phd Typical motor power. The power ratings apply to most IEC 60034 motors at nominal voltage
(400, 500 or 690 V).
Derating
The load capacity (current and power) decreases if the installation site altitude exceeds 1000 metres
(3300 ft), or if the ambient temperature exceeds 40 C (104 F).
Temperature derating
In the temperature range +40 C (+104 F) to +50 C (+122 F) the rated output current is decreased
1% for every additional 1 C (1.8 F). The output current is calculated by multiplying the current given in
the rating table by the derating factor.
Example If the ambient temperature is +50 C (+122 F) the derating factor is 100% - 1 % 10 C =
90% or 0.90. The output current is then 0.90 I or 0.90 I . C
2N 2hd
Note: Icont.max rating is not allowed above 40 C (104 F).
Altitude derating
In altitudes from 1000 to 4000 m (3300 to 13123 ft) above sea level, the derating is 1% for every 100 m
(328 ft). For a more accurate derating, use the DriveSize PC tool. If the installation site is higher than
2000 m (6600 ft) above sea level, please contact your local ABB distributor or office for further
information.
Technical data
86
Technical data
87
DC Noise
DC fuses Power loss Air flow
Inverter unit type capacitance level
F Qty Type (Bussmann) dBA W (Btu/h) m3/h (ft3/min)
ACS800-107-0320-5 8200 2 170M8545 72 3900 (13300) 1280 (750)
ACS800-107-0400-5 10250 2 170M8552 72 4700 (16100) 1280 (750)
ACS800-107-0460-5 12300 2 170M8547 72 5700 (19500) 1280 (750)
ACS800-107-0610-5 14350 2 170M8550 72 7700 (26300) 1280 (750)
ACS800-107-0910-5 24600 4 170M8547 74 11000 (38000) 2560 (1510)
ACS800-107-1210-5 28700 4 170M8550 74 15000 (51000) 2560 (1510)
ACS800-107-1820-5 43050 6 170M8550 76 22000 (75000) 3840 (2260)
ACS800-107-2430-5 57400 8 170M8550 76 29000 (99000) 5120 (3010)
ACS800-107-3030-5 71750 10 170M8550 77 36000 (123000) 6400 (3770)
ACS800-107-3640-5 86100 12 170M8550 78 43000 (147000) 7680 (4520)
UN = 690 V
ACS800-107-0011-7 670 2 170M2674 62 300 (1020) 103 (61)
ACS800-107-0016-7 670 2 170M2676 62 340 (1160) 103 (61)
ACS800-107-0020-7 670 2 170M2676 62 440 (1500) 103 (61)
ACS800-107-0025-7 670 2 170M2679 62 530 (1810) 103 (61)
ACS800-107-0030-7 670 2 170M2679 62 610 (2080) 103 (61)
ACS800-107-0040-7 670 2 170M2680 62 690 (2360) 103 (61)
ACS800-107-0050-7 1330 2 170M2680 62 840 (2870) 250 (147)
ACS800-107-0060-7 1330 2 170M2682 62 1000 (3400) 250 (147)
ACS800-107-0075-7 1530 2 170M2682 72 1100 (3760) 480 (283)
ACS800-107-0105-7 3070 2 170M4700 72 1500 (5120) 480 (283)
ACS800-107-0125-7 3070 2 170M4700 72 1800 (6150) 480 (283)
ACS800-107-0145-7 3070 2 170M6301 72 2300 (7850) 480 (283)
ACS800-107-0175-7 3070 2 170M6301 72 2500 (8540) 480 (283)
ACS800-107-0215-7 3070 2 170M6303 72 2900 (9900) 480 (283)
ACS800-107-0260-7 4600 2 170M8645 72 4000 (13700) 1280 (750)
ACS800-107-0320-7 6130 2 170M8646 72 4600 (15700) 1280 (750)
ACS800-107-0400-7 6130 2 170M8646 72 5200 (17800) 1280 (750)
ACS800-107-0440-7 7670 2 170M8647 72 6800 (23200) 1280 (750)
ACS800-107-0580-7 9200 2 170M8650 72 7400 (25300) 1280 (750)
ACS800-107-0870-7 15330 2 170M8647 74 13000 (44000) 2560 (1510)
ACS800-107-1160-7 18400 4 170M8650 74 14000 (48000) 2560 (1510)
ACS800-107-1740-7 27600 6 170M8650 76 21000 (72000) 3840 (2260)
ACS800-107-2320-7 36800 8 170M8650 76 28000 (96000) 5120 (3010)
ACS800-107-2900-7 46000 10 170M8650 77 35000 (120000) 6400 (3770)
ACS800-107-3490-7 55200 12 170M8650 78 42000 (143000) 7680 (4520)
ACS800-107-4070-7 64400 14 170M8650 78 49000 (167000) 8960 (5270)
ACS800-107-4650-7 73600 16 170M8650 79 55000 (188000) 10240 (6030)
ACS800-107-5230-7 82800 18 170M8650 79 62000 (212000) 11520 (6780)
ACS800-107-5810-7 92000 20 170M8650 79 69000 (236000) 12800 (7530)
ACS800-107-6390-7 101200 22 170M8650 79 76000 (260000) 14080 (8290)
ACS800-107-6970-7 110400 24 170M8650 79 83000 (283000) 15360 (9040)
00184674
Technical data
88
Motor connection
Voltage (U2) 0 to U1, 3-phase symmetrical, Umax at field weakening point
UNmains
fFWP = fNmotor
UNmotor
fFWP: frequency at field weakening point; UNmains: mains (input power) voltage;
UNmotor: rated motor voltage; fNmotor: rated motor frequency
Power limit 2 Phd. After approximately 2 minutes at 2 Phd, the limit is set at Pcont.max.
Motor cable lead-throughs 3 60 mm at each R8i inverter module (units without common motor terminal cubicle)
(Frame R8i and multiples) Units with common motor terminal cubicle: See chapter Dimensions.
Technical data
89
Output terminals
Bottom exit
(Frame R7i)
except ACS800-107-0145-3, Front view
-0175-3, -0145-5, -0175-5, Bolt size: M12 or
-0215-5, -0175-7 and -0215-7 Tightening torque: 70 Nm (52 lbf.ft)
with du/dt filters
Output terminals
Bottom exit
(Frame R7i)
ACS800-107-0145-3, -0175-3, Side view
-0145-5, -0175-5, -0215-5, Bolt size: M12 or
-0175-7 and -0215-7 with du/dt Tightening torque: 70 Nm (52 lbf.ft)
filters
Technical data
90
Cabling
direction
Cabling direction
68265631-A0 cabinet_400_generic.asm
Technical data
91
Efficiency
Approximately 98% at nominal power level
Cooling
Method Internal fans, flow direction from bottom to top
Cooling air flow See section DC capacitance, DC fuses, noise, cooling characteristics above.
Degree of protection
IP22; IP42; IP54; IP54R (with air duct outlet)
Ambient conditions
Environmental limits for the drive are given below. The drive is to be used in a heated,
indoor, controlled environment.
Technical data
92
Materials
Cabinet Hot-dip zinc-coated (thickness approx. 20 m) sheet steel with polyester thermosetting
powder coating (thickness approx. 80 m) on visible surfaces except back panel. Colour:
RAL 7035 (light grey, semigloss).
Inverter modules PC/ABS 2.5 mm, colour NCS 1502-Y (RAL 90021 / PMS 420 C)
hot-dip zinc coated steel sheet 1.5 to 2 mm, thickness of coating 100 micrometres
cast aluminium AlSi (R2i and R3i)
extruded aluminium AlSi (R4i and R5i)
Fire safety of materials Insulating materials and non-metallic items mostly self-extinctive.
(IEC 60332-1)
Packaging Frame of wood or plywood with PE-LD wrapping and PP or steel bands.
Technical data
93
Disposal The drive contains raw materials that should be recycled to preserve energy and natural
resources. The package materials are environmentally compatible and recyclable. All
metal parts can be recycled. The plastic parts can either be recycled or burned under
controlled circumstances, according to local regulations. Most recyclable parts are marked
with recycling marks.
If recycling is not feasible, all parts excluding electrolytic capacitors and printed circuit
boards can be landfilled. The DC capacitors (C1-1 to C1-x) contain electrolyte and the
printed circuit boards contain lead, both of which are classified as hazardous waste within
the EU. They must be removed and handled according to local regulations.
For further information on environmental aspects and more detailed recycling instructions,
please contact your local ABB distributor.
Technical data
94
Technical data
95
Circuit diagrams
Circuit diagrams
96
Circuit diagrams
97
Circuit diagrams
98
Circuit diagrams
99
Circuit diagrams
100
Circuit diagrams
101
Circuit diagrams
102
Circuit diagrams
103
Circuit diagrams
104
Circuit diagrams
105
Circuit diagrams
106
Circuit diagrams
107
Circuit diagrams
108
Circuit diagrams
109
Circuit diagrams
110
Circuit diagrams
111
Circuit diagrams
112
R8i inverter unit - I/O and control (Safe torque off, +Q967)
Circuit diagrams
113
Circuit diagrams
114
2R8i inverter unit - I/O and control (Safe torque off, +Q967)
Circuit diagrams
115
Circuit diagrams
116
Circuit diagrams
117
Example - Safe torque off with a safety relay (+Q968), frames R2i-R4i
Circuit diagrams
118
Example - Safe torque off with a safety relay (+Q968), frame R5i
Circuit diagrams
119
Example - Safe torque off with a safety relay (+Q968), frame R7i
Circuit diagrams
120
Example - Safe torque off with a safety relay (+Q968), frame R8i
Circuit diagrams
121
Dimensions
terminal cubicle
terminal cubicle
Common motor
Common motor
Control cubicle
weight kg (lbs)
1R8i inverter
2R8i inverter
3R8i inverter
2R8i inverter
3R8i inverter
3R8i inverter
2R8i inverter
3R8i inverter
Shipping split
Approximate
Frame size
modules
modules
modules
modules
modules
modules
cubicles
module
widths
Dimensions
122
IP22/42 IP54
Dimensions
123
Dimensions
124
400 mm
Dimensions
125
600 mm
Dimensions
126
Dimensions
Further information
Product and service inquiries
Address any inquiries about the product to your local ABB representative, quoting the type
designation 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 Sales,
Support and Service network.
Product training
For information on ABB product training, navigate to www.abb.com/drives and select
Training courses.