Acs 800

ACS800
Hardware manual
ACS800-07 (+V992) drives (500 to 2800 kW)
ACS800-07 manuals
Hardware manual
ACS800-07 (+V992) Drives (500 to 2800 kW) Hardware Manual 3AUA0000068936 1)
Supply unit firmware manual
ACS800 Diode Supply Control Program Firmware Manual 3AUA0000068937 1)
Inverter unit firmware manual (Drive application program firmware manual)
Standard Control Program Firmware Manual 3AFE64527592 2)
System Control Program Firmware Manual 3AFE64670646 2)
etc
OPTION MANUALS
Fieldbus Adapters, I/O Extension Modules etc 2)
1) Delivered as a printed copy with the drive.

2) Delivered as a printed copy with the appropriate control program or option device of the drive.
All manuals are available as PDF documents on the Internet. See section Further information on the inside of the back
cover.
ACS800-07 (+V992) drives
500 to 2800 kW
Hardware manual
3AUA0000068936 REV A EN
EFFECTIVE: 2010-03-15
© 2010 ABB Oy. All Rights Reserved.

5
Safety instructions
What this chapter contains

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

There are two types of safety instructions throughout this manual: warnings and
notes. Warnings caution you about conditions which can result in serious injury or
death and/or damage to the equipment, and advise on how to avoid the danger.
Notes draw attention to a particular condition or fact, or give information on a
subject. The warning symbols are used as follows:
Dangerous voltage warning warns of high voltages which can cause

physical injury and/or damage to the equipment.
General warning warns about conditions, other than those caused by

electricity, which can result in physical injury and/or damage to the
equipment.
Electrostatic discharge warning warns of electrostatic discharge which
can damage the equipment.
Safety instructions
6
Installation and maintenance work

These warnings are intended for all who work on the drive, motor cable or motor.
Ignoring the instructions can cause physical injury or death, or damage the
equipment.
WARNING!
• Only qualified electricians are allowed to install and maintain the drive.
• Before starting the work on any part of the drive, isolate it from the power line
with the main disconnecting device (main breaker or main switch-disconnector).
The main switch-disconnector or main breaker does not remove the voltage
from the input busbars of the drive.
• Never work on the drive, the motor cable or the motor when main power is
applied. After switching off the input power, always wait for 5 minutes to let the
intermediate circuit capacitors discharge before you start working on the drive,
the motor or the motor cable. Measure the voltage between terminals UDC+
and UDC- (L+ and L–) with a multimeter (impedance at least 1 Mohm) to
ensure that the drive is discharged before beginning work.
• Before working on any part of the drive, isolate its auxiliary circuits from the
power supply with the auxiliary voltage switch [Q10].
• Apply temporary grounding before working on the unit.
• Do not work on the control cables when power is applied to the drive or to the
external control circuits. Externally supplied control circuits may cause
dangerous voltages to exist inside the drive even when the main power of the
drive is switched off.
• Do not make any insulation or voltage withstand tests on the drive or drive
modules.
• When reconnecting the motor cable, always check that the phase order is
correct.
• When joining shipping splits (if any), check the cable connections at the joints
before switching on the supply voltage.
• Live parts on the inside of the doors are protected against direct contact.
Special attention shall be paid when handling metallic shrouds.
• After maintaining or modifying a drive safety circuit or changing circuit boards

inside the module, retest the functioning of the safety circuit according to the
start-up instructions.
• Do not change the electrical installations of the drive except for the essential
control and power connections. Changes may affect the safety performance or
operation of the drive unexpectedly. All customer-made changes are on the
customer's responsibility.
Safety instructions
7
Note:
• The main disconnecting device (main breaker or main switch-disconnector)

does not switch off the voltage from the auxiliary circuits or the input busbars.
• The motor cable terminals on the drive are at a dangerously high voltage when
the input power is on, regardless of whether the motor is running or not.
• The brake control terminals (UDC+, UDC-, R+ and R- terminals) carry a

dangerous DC voltage (over 500 V).
• Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V)

may be present on the relay outputs of the drive system.
• The Prevention of unexpected start-up function does not remove the voltage
from the main and auxiliary circuits.
• The Safe torque off function does not remove the voltage from the main and
auxiliary circuits.
WARNING!
• During the installation procedure, the inverter modules may have to be

temporarily extracted from the cabinet. The modules have a high center of
gravity. In order to minimise the danger of toppling over, keep the support legs
of the modules extended whenever manoeuvring the modules outside the
cabinet.
• Electrically conductive dust inside the unit may cause damage or lead to
malfunction. Make sure that dust from drilling does not enter the drive when
installing.
• Fastening the cabinet by riveting or welding is not recommended. However, if

welding is necessary, ensure the return wire is properly connected in order not
to damage the electronic equipment in the cabinet. Also ensure that welding
fumes are not inhaled.
• Ensure sufficient cooling of the unit.
• Cooling fans may continue to rotate for a while after the disconnection of the
electrical supply.
• Some parts inside the drive cabinet, such as heatsinks of power

semiconductors, remain hot for a while after the disconnection of the electrical
supply.
WARNING!
• The printed circuit boards contain components sensitive to electrostatic

discharge. Wear a grounding wrist band when handling the boards. Do not
touch the boards unnecessarily.
Safety instructions
8
Grounding
These instructions are intended for all who are responsible for the grounding of the
drive. Incorrect grounding can cause physical injury, death or equipment malfunction
and increase electromagnetic interference.
WARNING!
• Ground the drive, motor and adjoining equipment to ensure personnel safety in
all circumstances, and to reduce electromagnetic emission and pick-up.
• Make sure that grounding conductors are adequately sized as required by

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

earth (PE).
• Do not install a drive equipped with an EMC (line) filter to an ungrounded

power system or a high resistance -grounded (over 30 ohms) power system.
Note:
• Power cable shields are suitable for equipment grounding conductors only
when adequately sized to meet safety regulations.
• As the normal leakage current of the drive is higher than 3.5 mA AC or

10 mA DC, a fixed protective earth connection is required by EN 61800-5-
1, 4.3.5.5.2. The cross-section of the protective earthing conductor must be at
least 10 mm2 Cu or 16 mm2 Al.
Fibre optic cables
WARNING!
• Handle the fibre optic cables with care. When unplugging optic cables, always
grab the connector, not the cable itself. Do not touch the ends of the fibres with
bare hands as the fibre is extremely sensitive to dirt. The minimum allowed
bend radius is 35 mm (1.4”).
Safety instructions
9
Operation
These warnings are intended for all who plan the operation of the drive or operate
the drive. Ignoring the instructions can cause physical injury or death or damage the
equipment.
WARNING!
• If the drive is equipped with an optional brake unit, make sure there are
inverters connected to the intermediate circuit before start. As a rule of thumb,
the sum capacitance of the inverters connected must be at least 30% of the
sum capacitance of all inverters.
• Close the switch fuses of all parallel-connected inverters before start.
• Do not open the DC switch fuse of an inverter when the inverter is running.
WARNING!
• Before adjusting the drive and putting it into service, make sure that the motor
and all driven equipment are suitable for operation throughout the speed range
provided by the drive. The drive can be adjusted to operate the motor at
speeds above and below the speed provided by connecting the motor directly
to the power line.
• Do not activate automatic fault reset functions of the drive control program if
dangerous situations can occur. When activated, these functions will reset the
drive and resume operation after a fault.
• Do not control the motor with the disconnecting device (means); instead, use
the control panel keys and , or commands via the I/O board of the drive.
The maximum allowed number of charging cycles of the DC capacitors (ie,
power-ups by applying power) is five in ten minutes.
Note:
• If an external source for start command is selected and it is ON, the drive will
start immediately after fault reset unless the drive is configured for 3-wire (a
pulse) start/stop.
• When the control location is not set to Local (L not shown in the status row of
the display), the stop key on the control panel will not stop the drive. To stop
the drive using the control panel, press the LOC/REM key and then the stop
key .
Safety instructions
10
Permanent magnet motor drives

These are additional warnings concerning permanent magnet motor drives.
WARNING! Do not work on the drive when the permanent magnet motor is rotating.
Also when the supply power is switched off, a rotating permanent magnet motor
feeds power to the intermediate circuit of the drive and also the supply connections
become live (even when the inverter is stopped!).
Installation and maintenance work

• Disconnect the motor from the drive with a safety switch
and additionally, if possible,
• Lock the motor shaft and ground the motor connection terminals temporarily by
connecting them together as well as to the PE.
Operation
Do not run the motor above the rated speed. Motor overspeed leads to overvoltage
which may result in explosion of the capacitors in the intermediate circuit of the drive.
Application program
To control a permanent magnet motor, only use the ACS800 permanent magnet
synchronous motor drive application program, or other application programs in the
scalar control mode.
Safety instructions
11
Table of contents
ACS800-07 manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety instructions
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Usage of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fibre optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Application program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Table of contents
About this manual

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Categorization according to the frame size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation and commissioning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hardware description
ACS800-07 (+V992) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Cabinet line-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Single-line circuit diagram of the drive, example 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Single-line circuit diagram of the drive, example 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Layout drawing, example 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Layout drawing, example 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Swing-out frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Power connections and control interfaces of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Controls of the inverter unit (and motor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Analog and digital I/O signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Controls of the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Main disconnecting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Auxiliary voltage switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Grounding switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Table of contents
12
Other operating switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Analog and digital I/O signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Fieldbus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Power loss ride-through function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Ground fault monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Reduced run function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Type designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Mechanical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Moving the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
…by crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
…by fork-lift or pallet truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
…on rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Laying the unit on its back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Final placement of the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Fastening the cabinet to the floor (Non-marine units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Holes inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Fastening the unit to the floor and wall (Marine units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Joining the shipping splits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Connecting the DC busbars and the PE busbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
DC busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
PE busbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Cable duct in the floor below the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Cooling air intake through bottom of cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Electric welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Planning the electrical installation

Motor selection and compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Selecting the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Permanent magnet synchronous motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Thermal overload protection of the drive and the input and motor cables . . . . . . . . . . . . . . .62
Thermal overload protection of the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Protection against short-circuit in the motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Table of contents
13
Protection against short-circuit inside the drive or in the supply cable . . . . . . . . . . . . . . . . . 62

Ground fault protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Emergency stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Restarting after an emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Prevention of unexpected start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Safe torque off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Power factor compensation capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Equipment connected to the motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Installation of safety switches, contactors, connection boxes, etc . . . . . . . . . . . . . . . . . . . . . 69
Bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Before opening an output contactor (in the DTC motor control mode) . . . . . . . . . . . . . . . . . 70
Relay output contacts and inductive loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Coaxial cable (for use with Advant Controllers AC 80/AC 800) . . . . . . . . . . . . . . . . . . . . . . . 71
Connection of a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Installation sites above 2000 metres (6562 feet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Electrical installation
Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Supply cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
External earth fault in IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Input power connection – Units without main switch-disconnector
or main breaker (no option +F253 or +F255) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Six-pulse connection, two DSU modules in parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Twelve-pulse connection, two DSU modules in parallel . . . . . . . . . . . . . . . . . . . . . . . . 78
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Phase I – Removing the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Phase 2 – Installing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Phase 3 – Replacing the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Use of the dual-cable screw lug connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Removal of the dual-cable screw lug connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Input power connection – Units with main switch-disconnector
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or main breaker (option +F253 or +F255) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Six-pulse connection, two DSU modules in parallel . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Twelve-pulse connection, two DSU modules in parallel . . . . . . . . . . . . . . . . . . . . . . . .85
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Motor connection – Units without common motor terminal cubicle (no option +H359) . . . . . . . . . .87
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Motor connection – Units with common motor terminal cubicle (option +H359) . . . . . . . . . . . . . . .91
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Drive/inverter control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Supply unit control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Installation of optional modules and PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Cabling of I/O and fieldbus modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Cabling of pulse encoder interface module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Fibre optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Connections and tap settings of the auxiliary voltage transformer of the drive . . . . . . . . . . . . . . . .96
Switching on and selecting the supply voltage of the auxiliary
voltage transformer of the DSU module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Installation of brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Motor control and I/O board (RMIO)

Note on cabinet-installed ACS800 drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Note on the terminal labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
External control connections (non-US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
External control connections (US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
RMIO board specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Analogue inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Constant voltage output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Auxiliary power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Analogue outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
DDCS fibre optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
24 VDC power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Installation checklist and start-up

Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Basic checks with no voltage connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Connecting voltage to input terminals and auxiliary circuit . . . . . . . . . . . . . . . . . . . . . . . . . .107
Starting the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Setting up the supply unit control program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Setting up the drive application program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
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On-load checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Maintenance
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Redundancy (Reduced run capability) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Removing a DSU module and selecting the Reduced run feature . . . . . . . . . . . . . . . . . . . 110
Removing an inverter module and selecting the Reduced run feature . . . . . . . . . . . . . . . . 112
Replacing the PPCS branching unit (APBU-xx) memory backup battery . . . . . . . . . . . . . . . . . . . 113
Checking and replacing the air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Checking the connections of the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Supply, inverter and brake module cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Replacing the fan of the supply module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Replacing the fan of the inverter and brake module . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Replacing the fans in the auxiliary control cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Replacing the fan in the incoming cubicle with the main breaker (option +F255) . . . . . . . . 118
Replacing the additional fans in the IP54 / UL type 12 drives (+B055 and +B059) . . . . . . . 119
Heatsinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Cleaning the heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Reforming the electrolytic capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Capacitor replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Safety function checks in the maintenance routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Other maintenance actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Replacement of a supply inverter or brake modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Fault tracing
Supply module LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Other LEDs of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Technical data
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
ACS800-07 (+V992) frame sizes and power module types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
AC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
DC fuses at inverter module input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Fuses for main circuit voltage measurement for the BAMU board . . . . . . . . . . . . . . . . . . . . . . . . 129
Fuses on the CVAR board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
DC fuses for the DSU module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Input power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
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16
Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132

Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Tightening torques for power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Compliance with the EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Compliance with the EN 61800-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
First environment (PDS of category C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Second environment (PDS of category C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
Second environment (PDS of category C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
“C-tick” marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Compliance with IEC 61800-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
First environment (restricted distribution) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Second environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Dimensions
Cabinet line-ups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
1×D4 + 2×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
2×D4 + 2×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
2×D4 + 4×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
3×D4 + 3×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
3×D4 + 4×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
2×D4 + 3×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
3×D4 + 6×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
4×D4 + 6×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
3×D4 + 5×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Frame size 1×D4 + 2×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
Frame size 1×D4 + 2×R8i (with a main switch-disconnector +F253) . . . . . . . . . . . . . . . . . . . . . . .151
Frame size 1×D4 + 2×R8i (with top entry/exit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
Frame size 2×D4 + 2×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Frame size 2×D4 + 3×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
Frame size 2×D4 + 3×R8i (with a main breaker +F255) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
Frame size 3×D4 + 4×R8i (with a main breaker +F255) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
Common motor terminal cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
300 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
400 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187
600 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188
Table of contents
17
Resistor braking
Resistor braking options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Chopper/Resistor combinations – Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Brake resistors – Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Verifying the capacity of the braking equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Custom resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Calculating the maximum braking power (Pbr) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Example 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Example 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Example 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Custom resistor installation and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Brake circuit commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Further information
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Table of contents
18
Table of contents
19
About this manual

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

Some instructions, technical data and dimensional drawings which concern only
certain drive frame sizes are marked with the symbol of the frame size (such as
“1×D4 + 2×R8i”, etc). The frame size is not marked on the drive designation label.
To identify the frame size of your drive, see the rating tables in chapter Technical
data.
About this manual

20
Contents
The chapters of this manual are briefly described below.
Safety instructions gives safety instructions for the installation, commissioning,
operation and maintenance of the drive.
About this manual introduces this manual.
Hardware description describes the drive.
Mechanical installation instructs how to move, place and mount the drive.
Planning the electrical installation provides advice on motor and cable selection, the
protective functions of the drive, and cable routing.
Electrical installation describes the cabling and wiring of the drive.
Motor control and I/O board (RMIO) shows external control connections to the motor
control and I/O board and its specifications.
Installation checklist and start-up helps in checking the mechanical and electrical
installation of the drive.
Maintenance contains preventive maintenance instructions.
Fault tracing contains troubleshooting instructions.
Technical data contains the technical specifications of the drive, eg, ratings, frame
sizes and technical requirements, provisions for fulfilling the requirements for CE
and other markings and warranty policy.
Dimensions contains information on the dimensions of the drive.
Resistor braking describes how to select, protect and wire optional brake choppers
and resistors.
About this manual

21
Installation and commissioning flowchart
Task See
Plan the installation. Technical data

Check the ambient conditions, ratings, required Planning the electrical installation
cooling air flow, input power connection, compatibility Option manuals (if optional equipment is
of the motor, motor connection, and other technical included)
data.
Select the cables.
Unpack and check the units. Check the number of Mechanical installation
DSUs. Hardware description
Check the type designation indicated by the type For instructions on how to disconnect the EMC/
designation label with the original order. If the drive is RFI filtering, contact your local ABB
about to be connected to an IT (ungrounded) system, representative.
check that the drive is not equipped with EMC/RFI
If the converter has been non-operational for
filtering (option +E202). Check that all necessary
more than one year, the converter DC link
optional modules and equipment are present and
capacitors need to be reformed. Contact your
correct.
local ABB representative for more information.
Only intact units may be started up.
Check the installation site. Mechanical installation, Technical data
Route the cables. Planning the electrical installation: Routing the

cables
Mount the cabinet line-up. Mechanical installation
Check the insulation of the motor and the motor Electrical installation: Checking the insulation of
cable. the assembly
Connect the power cables. Connect the control and Mechanical installation, Planning the electrical
the auxiliary control cables. installation, Electrical installation, Resistor
braking (optional)
Check the installation. Installation checklist and start-up
Commission the drive. Installation checklist and start-up
Commission the optional brake chopper (if present). Resistor braking
About this manual

22
Terms and abbreviations

Term/Abbreviation Explanation
ADPI Control panel interface board
APBU Branching unit used for making parallel connections for both supply
units and inverter modules
BAMU Main voltage measurement board
CDP312R Control panel
CINT Module interface board
CMIB Interface board to the main circuit thyristors and current

measurements
CVAR Varistor board
Diode supply module See supply module

The rectifier consists of diodes (or diodes and thyristors).
Diode supply unit See supply unit and diode supply module.
DSU module Diode supply module
Frame (size) Relates to the construction type of the component in question

For example, several drive types with different power ratings may
have the same basic construction, and this term is used in reference
to all those drive types.
With the ACS800-07 (+V992) (> 500 kW), the frame size of the drive
indicates the quantity and frame size of the supply modules, plus the
quantity and frame size of the inverter modules, eg, “2×D4 + 4×R8i”.
To determine the frame size of a drive type, see the rating tables in
the chapter Technical data.
Inverter Converter which converts direct current (DC) and voltage into
alternating current (AC) and voltage
Inverter module Inverter and related auxiliary devices enclosed inside a metal frame
or enclosure
The inverter module is one of the major building blocks in a cabinet-
installed drive.
Inverter unit Inverter module(s) under control of one control board, and the
related auxiliary devices
Typically, one inverter unit controls one motor. There is one inverter
unit in a single drive (such as ACS800-07) and several in a
multidrive installation.
Multidrive Drive for the control of several motors which are typically coupled to
the same machinery
There are one supply unit and several inverter units in a multidrive.
RDCO Satellite board that can be snapped on the RMIO board to add the
number of fibre optic channels available
About this manual

23
Term/Abbreviation Explanation
RDCU Drive control unit

The RDCU consists of a control board (RMIO) enclosed inside a
plastic casing for an easy snap-on installation. There are two
RDCUs in a large single drive: one for the supply unit (supply unit
control board) and the other for the inverter unit (inverter unit control
board).
Rectifier Converts alternating current (AC) and voltage into direct current
(DC) and voltage
RMIO Motor control and I/O board

The RMIO board is a versatile control board and an I/O interface. Its
use is determined by the control program loaded into the board. The
RMIO board is widely used in the ACS800 product series. It is used
for controlling drive modules, inverter units, supply units, cooling
units, brake units, etc. See also RDCU.
Single drive Drive for the control of one motor
Supply module Rectifier and related auxiliary devices enclosed inside a metal frame
or enclosure
The supply module is one of the major building blocks of a cabinet-
installed drive.
Supply unit Supply module(s) under control of one control board, and the related
auxiliary devices
There is one supply unit in a drive.
UPS Uninterruptible power supply
About this manual

24
About this manual

25

This chapter describes the construction of the drive in short.
ACS800-07 (+V992)
ACS800-07 (+V992) is a cabinet-mounted drive for controlling AC motors.
Cabinet line-up
The drive consists of several cubicles that contain the supply and motor terminals,
1 to 4 diode supply module(s), 2 to 6 inverter modules, and optional equipment. The
actual arrangement of the cubicles vary from type to type and the selected options.
See chapter Dimensions for the different line-up variations.
26
Single-line circuit diagram of the drive, example 1
Supply unit Inverter unit
400 VAC
M
3~
Input
power
line
Notes:
400 VAC The diagram shows drive type
ACS800-07-0610-3+F250 comprising:
230/115 VAC
– one DSU module and inverter
u
module (D4 + R8i)
Voltage
measurement – main switch-disconnectors inside the
u DSU module
(BAMU)
– main contactors inside the DSU
CVAR module (option +F250)
27
Single-line circuit diagram of the drive, example 2
Supply unit Inverter unit
M M
400 VAC 400 VAC
M Notes:
3~ The diagram shows drive type
Main
supply ACS800-07-0870-3+F250+F253+F260
comprising:
– two parallel DSU modules and two parallel
400 VAC inverter modules (2×D4 + 2×R8i)
230/115 VAC – main switch-disconnector (option +F253)
– main AC fuses (option +F260)
Voltage
u measurement – main contactors inside the DSU modules
(BAMU) (option +F250).
u
CVAR
28
Layout drawing, example 1

The following drawing shows an ACS800-07-0610-3+F250 drive type comprising:
• one DSU module and two parallel inverter modules (1×D4 + 2×R8i)
• main switch-disconnector inside the DSU module (internal main switch-
disconnectors)
• main contactors (option +F250) inside the DSU module.
Auxiliary control cubicle Supply module cubicle Inverter module cubicle
No. Description
1 Supply module.
+ Behind the module: input terminals.
+ Behind the module: quick connector.
7 10
2 Supply module switch-disconnector.
4
9 3 Supply unit control board (mounted
3 sideways).
4 Inverter DC fuses.
5 Inverter modules.
+ Behind each module: quick connector
for the inverter module output
connection.
+ Behind each module: output terminals.
8 Motor cables connect here if a common
motor terminal cubicle (option +H359) is
not present.
+ Motor (output) cable lead-throughs.
2 Not used if optional common motor
terminal cubicle is present.
1 6 Swing-out frame. Contains the inverter

unit control board with I/O terminals, and
5 5 provides space for standard and optional
electrical equipment.
+ Accessible by opening the swing-out
frame: auxiliary voltage transformer.
7 Auxiliary voltage switch-disconnector
with fuses.
8 Branching unit used for making a parallel
connection for inverter modules.
9 CVAR boards.
10 BAMU board.
29
Layout drawing, example 2

The following drawing shows drive type ACS800-07-0870-3+F253+F259+F260
comprising:
• two parallel DSU modules and two parallel inverter modules (2×D4 + 2×R8i)
• optional main switch-disconnector (option +F253) and grounding switch (option
+F259)
• main AC fuses (option +F260)
• main contactors (option +F250) inside the DSU modules.
Auxiliary control Incoming Supply module Inverter module

cubicle cubicle cubicle cubicle
10 14
13 7
6 4
12
3
5 5 8 8
11
1
See the legend on the following page.
30
No. Description
1 Input busbars.
2 Main switch-disconnector (option +F253) in a dedicated cubicle.
3 Grounding switch (option +F259).
4 AC fuses. Only present if the drive is equipped with a main switch-disconnector or main breaker.
5 Supply modules.
+ Behind each module: quick connector.
6 Supply unit control board (mounted sideways).
7 Inverter DC fuses.
8 Inverter modules.
+ Behind each module: quick connector for the inverter module output connection.
+ Behind each module: output terminals. Motor cables connect here if a common motor terminal cubicle (option +H359) is not present.
+ Motor (output) cable lead-throughs.
9 Swing-out frame. Contains the inverter unit control board with I/O terminals, and provides space for standard and optional electrical equipment.
+ Accessible by opening the swing-out frame: auxiliary voltage transformer.
10 Auxiliary voltage switch-disconnector.
11 APBU board for communication between the DSU control board and the parallel-connected DSU modules.
12 APBU board for communication between the inverter unit control board and the parallel-connected inverter modules.
13 CVAR boards.
14 BAMU board.
31
Swing-out frame
The swing-out frame inside the auxiliary control cubicle provides space for the
inverter unit control board, control electronics of the drive, I/O terminal blocks, and
optional electrical equipment. The lead-throughs for I/O cables, the auxiliary voltage
transformer, and further space for additional equipment are available behind the
frame. The frame can be opened by removing the two locking screws and moving
the swing-out frame aside. (Depending on selected options, actual equipment of the
drive may differ from what is depicted below.)
Inverter unit
control board with
I/O terminal blocks
Terminal block X2
(optional)
Terminal block X1
Switch for auxiliary

voltage
24 V DC
Branching unit
(needed when
there are more
than one supply Buffering module
unit) for auxiliary
voltage
24 V DC / 20 A
32
Power connections and control interfaces of the drive

The following diagram illustrates the power connections and control interfaces of the
drive. The table below gives some additional information on the numbered items.
X20
X20
1 1
0 S Control 0 VDC 1 Control 0 VDC 1
2 2
1
panel +24 VDC 1
panel +24 VDC
Back up c 3 Back up c 3
G
ER EN
EM
CY
X21
X21
STO P
Fault Power Fault Power
RESET 4
12 12
6
5 1 SLOT 1 1 SLOT 1
X22
X22
1
7
11 SLOT 2 11 SLOT 2
1 1
X23
X23
2 RDCO 2 RDCO
n 1 1
3
0
X25
X25
X1 3
DDCS 3
DDCS
1 1
X26
X26
3 3
1
BAMU 1
X27
X27
3 3
[RDCU (RMIO)] [RDCU (RMIO)]

3
1 X1 n 1 X50 n
L1 U2
L2 V2
1 2
L3 W2
No. Description See also page
1 Input power and PE connection terminals 51, 52, 75
2 Motor connection terminals 87, 91, 132
3 Terminal block on the inverter control unit for the user-defined digital and analogue control 33
signals
4 Control panel 33
5 Operation switches: main contactor/breaker control and supply unit start, emergency stop, reset 34
etc.
Composition vary depending on the options in use.
6 Slot 1 on the inverter control unit for an optional I/O extension module (RAIO, RDIO), pulse 95
encoder interface module (RTAC), or fieldbus adapter module (eg, RMBA, RDNA, RPBA)
7 Slot 2 on the inverter control unit for an optional I/O extension module (RAIO, RDIO) or pulse 95
encoder interface module (RTAC)
33
Controls of the inverter unit (and motor)

The inverter control program runs in the RDCU control unit located in the swing-out
frame. The RDCU is connected to the inverter modules by a fibre optic link,
distributed through an optical branching unit. In the inverter modules, the optic link
connects to the AINT board, the terminals of which are accessible through a hole on
the front panel of the module.
The user controls the inverter unit (and motor) with the control panel, the I/O
interface on the control board or through the fieldbus interface.
Control panel
A control panel is installed on the door of the drive. The panel is the user interface of
the inverters of the drive, providing the essential controls such as Start/Stop/
Direction/Reset/Reference, and the parameter settings for the drive application
program. The panel can also be used for the set-up and monitoring of the supply
unit. See the Firmware manual of the drive application program and ACS800 diode
supply control program firmware manual (3AUA0000068937[English]) for further
information.
Analog and digital I/O signals

For the default I/O diagram, see External control connections (non-US) and External
control connections (US).
Fieldbus
See the appropriate Firmware manual of the drive application program.
34
Controls of the supply unit

The supply unit control program runs in the RDCU control unit located in the swing-
out frame. The RDCU is connected to the supply modules by a fibre optic link, and a
separate wire set. If there are parallel supply modules, the controls from the RDCU
are distributed to the modules with an optical branching unit (APBU board). The
RDCU is also connected to the inverter unit with a fibre optic link and to the panel
through the panel link.
Typically, the user controls the supply unit with the control devices mounted on the
cabinet door. The use of these control devices is described in the following
subsections. No additional control devices or connections are needed. However, it is
also possible to control the unit with the control panel and through the fieldbus.
Main disconnecting device

The drive is always equipped with a main disconnecting device. The device is either
the main switch-disconnector inside the module (no option +F253 or +F255), the
main switch-disconnector outside the module (option +F253), or the main breaker
outside the module (option +F255).
The user operates the main switch-disconnector(s) with a handle on the cabinet
door. The breaker is withdrawable; its must be racked out when disconnection is
needed.
WARNING! The main disconnecting device does not switch off the auxiliary
voltages inside the cabinet.
Auxiliary voltage switch

The auxiliary voltage switch controls the voltage supply for the auxiliary circuits.
Note: If the drive is equipped with an uninterruptible power supply (option +G307)
there is also an additional switch-disconnector inside the cabinet for the UPS circuit.
Grounding switch
A grounding switch for the temporary grounding is an option (+F259). The user
operates the switch from a handle on the cabinet door.
Other operating switches

Depending on the drive options, the switches shown in the drawing below may be
mounted on the door of the cabinet.
35
Emergency stop and supply Operating switch [only in units

unit fault reset button with main contactors (option
(optional) +F250) or breaker (option
+F255)]
Emergency stop button

(optional)
Note: On units without the line contactor option (+F250), main breaker option
(+F255) or the main switch-disconnector option (+F253), the supply unit will start
rectifying as soon as the user closes the switch-disconnector(s) of the supply
module(s). There is no separate operating switch for the start on the cabinet door.
Control panel
There is one panel on the cabinet door which communicates with the inverter unit as
standard. However, the panel link is also wired to the control board of the supply
unit. You can change the communication from the inverter unit to the supply unit,
after which it is possible to:
• view and reset fault and warning messages, and view the fault history
• view actual signals
• change parameter settings
• change between the local and external control and, in the local control, start and
stop the supply unit.
For the instructions on the use of the panel, see the appropriate Firmware manual of
the drive application program. For details on the supply unit control program, see
ACS800 diode supply control program firmware manual
(3AUA0000068937[English]).
Analog and digital I/O signals

The diagram below shows the I/O signal connections of a standard diode supply
unit.
Note: The I/O setting is reserved for the internal use. Do not change the wiring.
Note: The I/O connections of the delivery may vary somewhat from what is
represented depending on which options are in use. Always refer to the circuit
diagram set delivered with the drive if in doubt of the applicability.
36
The default cable connections to the RMIO board of the DSU are shown below.
X20
Terminal block size: 1 VREF- Reference voltage -10 VDC,
cables 0.3 to 3.3 mm2 (22 to 12 AWG) 2 GND 1 kohm < RL < 10 kohm
Tightening torque: X21
0.2 to 0.4 Nm (2 to 4 lbf in.) 1 VREF+ Reference voltage 10 VDC,
2 GND 1 kohm < RL < 10 kohm
3 AI1+ By default, not in use. 0(2) …10 V,
4 AI1- Rin > 200 kohm
5 AI2+ By default, not in use. 0(4) …20 mA,
6 AI2- Rin = 100 ohm
7 AI3+ By default, not in use. 0(4) …20 mA,
1 3 * Three-position operating Rin = 100 ohm
8 AI3-
switch
9 AO1+ By default, not in use. 0(4) … 20 mA,
2 4 RL < 700 ohm
10 AO1-
0
1 11 AO2+ By default, not in use. 0(4) …20 mA,
START
12 AO2- RL < 700 ohm
1)
Non-programmable I/O X22
1 DI1 Overtemperature supervision 1)
2)
External alarm/fault indication via * 2 DI2 On / Off 1)
2
digital input DI4: See parameter 30.04 3 DI3 Start ( rising edge start) 1)
DI4 EXT EVENT.
4
4 DI4 By default, not in use. 2)

3) External alarm/fault indication via 5 DI5 Fault (0) 3)
digital input DI5: See parameter 30.05 6 DI6 Reset 1)
DI5 EXT EVENT. 7 +24V +24 VDC max. 100 mA
8 +24V
4) Acknowledgement from the main
9 DGND Digital ground
breaker (if in use). If there is no main
10 DGND Digital ground
breaker but the module-in-built
contactors are in use, the contactors 11 DI7(DIIL) By default, not in use. 4)
are monitored by the CMIB board. X23
1 +24V Auxiliary voltage output, non-isolated,
2 GND 24 VDC 250 mA
X25
1 RO11 Relay output 1: Running
2 RO12
3 RO13
X26
1 RO21 Relay output 2: Fault (-1)
2 RO22
3 RO23
X27
1 RO31 Relay output 3: Main contactor/
24 V DC / 115 V AC / 230 V AC 2 RO32 breaker control 1)
Contactor or breaker on/off 3 RO33
37
Fieldbus
For more information on the fieldbus communication, see ACS800 diode supply
control program firmware manual (3AUA0000068937[English]).
Power loss ride-through function

The power loss ride-through function keeps the supply unit operative over an
unexpected input power break. You can activate the function and define the delay
time in the DSU control program. For more information, see ACS800 diode supply
control program firmware manual (3AUA0000068937 [English]).
Note: Supply units equipped with a main breaker (option +F255) have the ride-
through function available only when a terminal for external control voltage (option
+G307) is used and supplied with UPS. With a main switch-disconnector (option
+F253) the ride-through function is available as standard also without the UPS.
Ground fault monitoring

Ground fault current monitoring is available on the inverter side for TN networks.
The DSU does not monitor ground current in an IT (ungrounded) network. However,
the unit can be equipped with an optional insulation monitoring device (option
+Q954). The device detects ground faults by monitoring the insulation resistance
between the power line and ground. When the resistance value goes below the
user-defined limit, the device evokes the DSU ground fault monitoring through a
digital input. You can define the DSU operation in an ground fault with the DSU
parameters. For more information, see the documentation of the monitoring device
delivered with the drive, and parameter group 30 in ACS800 diode supply control
program firmware manual (3AUA0000068937[English]).
Reduced run function

If one of the parallel-connected supply or inverter modules must be taken out of the
cabinet for service, it is possible to continue operation using the remaining modules
at reduced power. See Redundancy (Reduced run capability).
38
Type designation
The type code of the drive is indicated on the type designation label, attached on a
door of the supply unit. The type code contains information on the specifications and
configuration of the drive. The first digits from left express the basic configuration
(eg, ACS800-07-0610-3). The optional selections are given thereafter, separated by
+ signs (eg, +E202). The main selections are described below.
Note: The information below is for quick reference only and does not contain all
conditions and details. For more information, refer to ACS800 Ordering Information
(code: 64556568), available through ABB representatives.
Selection Alternatives
Product series ACS800 product series
Type 07 = cabinet-mounted
When no options are selected: IP21 (UL Type 1), main switch/
disconnector(s), 230 V auxiliary voltage, du/dt filtering (+E205), common
mode filtering (CMF) (+E208), EMC/RFI filtering for second environment
(+E210), drive control program, bottom entry/exit of cables, coated circuit
boards, set of English manuals.
Size Refer to Technical data: Ratings.
Voltage range 3 = 380/400/415 VAC
(nominal rating in bold) 5 = 380/400/415/440/460/480/500 VAC
7 = 525/575/600/690 VAC
+ options
I/O options Refer to ACS800 Ordering Information (3AFY64556568 [English]).
Fieldbus adapter
Application program
Degree of protection B053 = IP22 (UL Type 1)
B054 = IP42 (UL Type 1)
B055 = IP54 (UL Type 12) (Not available with +C134)
B059 = IP54R (with connection to air outlet duct)
Construction C121 = Marine construction (reinforced mechanical parts and fastening,
marking of conductors [A1], door handles, self-extinctive materials)
C129 = UL Listed (115 V AC auxiliary voltage, cable conduit entries, all
components UL listed/recognized, max. supply voltage 600 V; +F253,
+F260 and top entry of cables are standard)
C134 = CSA Approved (as +C129, with CSA approved components)
Filters E202 = EMC/RFI filtering for first environment TN (grounded) system,
restricted (A-limits). Only for 6-pulse ACS800-07-0610-3 and -0760-5.
Requires +F253 and +F260.
E206 = Sine output filters (Not available with +C121, +C129 or +C134)
Note: du/dt filtering (+E205), common mode filtering (CMF) (+E208), and
EMC/RFI filtering for second environment (+E210) are standard
equipment.
Resistor braking D150 = brake choppers
D151 = brake resistors (not available in IP54 or IP54R)
39
Line options F250 = main contactors inside the DSU modules
F253+F260 = aR AC fuses + main switch-disconnector (6-pulse) (Main
switch-disconnectors in DSU modules removed)
A004+F253+F260 = aR AC fuses + main switch-disconnector (12-pulse)
(Main switch-disconnectors in supply modules removed) (with +C129 and
+C134, second cubicle for main switch-disconnector added)
F255+F260 = main breaker (6-pulse only) (Not available with frame
1×D4 + n×R8i) (Main switch-disconnectors and main contactors in supply
modules removed)
F259 = grounding switch (only with +F253 or +F255) (Not available with
+C129 or +C134)
Version V992 = DSU version 2 not backward compatible with those diode supply
units that are not marked with the +V992 code
Cabling H351 = top entry (IP54 and IP54R require +F253 or +F255)
H353 = top exit
H358 = US/UK gland/conduit plate (standard with +C129 and +C134)
H359 = common motor terminal cubicle
Auxiliary voltage G304 = 115 VAC auxiliary voltage (standard with +C129 and +C134)
Cabinet options G300 = cabinet heaters (external supply) (Not available with option
+C129 or +C134)
G313 = motor heater output (external supply)
G307 = terminals for external control voltage (UPS)
G317 = busbar supply conductors (6-pulse only) (Requires option +F253
or +F255)
G330 = halogen-free wiring and materials (Not available with option
+C129 or +C134)
G338 = additional wire markings (Equipment pin numbers are printed on
wires between modules and on wires connected to equipment.)
G339 = additional wire markings (Equipment and terminal block pin
numbers are printed on wires between modules and on wires connected
to equipment and terminal blocks. Main circuit conductors are marked.)
G340 = additional wire markings (Equipment pin numbers are marked
with rings on wires between modules and on wires connected to
equipment, terminal blocks and detachable screw terminals. Main circuit
conductors are marked.)
G341 = additional wire markings (Equipment identifications and terminal
block pin numbers are marked by rings on optical fibres, on wires
between modules, and on wires connected to equipment, terminal blocks
and detachable screw terminals. Main circuit conductors and also short
and obvious connections are marked.)
G342 = additional wire markings (Equipment identifications and terminal
block pin numbers and remote addresses are marked by rings on optical
fibres, on wires between modules, and on wires connected to equipment,
terminal blocks and detachable screw terminals. Main circuit conductors
and also short and obvious connections are marked.)
Language of manuals Rxxx
Refer to ACS800 Ordering Information (3AFY64556568 [English]).
Starter of auxiliary motor M602 = 2.5 … 4 A (1, 2 or 4 pcs)
fan M603 = 4 … 6.3 A (1, 2 or 4 pcs)
M604 = 6.3 … 10 A (1, 2 or 4 pcs)
M605 = 10 … 16 A (1 or 2 pcs)
M606 = 16 … 25 A (1 pc)
40
Safety features Q950 = prevention of unexpected start-up (Category 3)
Q951 = emergency stop, stop category 0 with opening the main
contactor/breaker
Q952 = emergency stop, stop category 1 with opening the main
contactor/breaker
Q954 = ground fault monitoring (IT [ungrounded] system)
Q959 = red-coloured trip pushbutton for external breaker
Q963 = emergency stop, stop category 0 without opening the main
contactor/breaker
Q964 = emergency stop, stop category 1 without opening the main
contactor/breaker SS1
Q968 = safe torque off with a safety relay
Special P902 = customised (described in Technical appendix on ordering)
P904 = extended warranty
P913 = special colour
41

This chapter describes the mechanical installation procedure of the drive.
General
See chapter Technical data for allowable operating conditions and requirements for
free space around the unit.
The unit should be installed in an upright vertical position.
The floor that the unit is installed on should be of non-flammable material, as
smooth as possible, and strong enough to support the weight of the unit. The floor
flatness must be checked with a spirit level before the installation of the cabinets into
their final position. The maximum allowed deviation from the surface level is 5 mm in
every 3 metres. The installation site should be levelled, if necessary, as the cabinet
is not equipped with adjustable feet.
The wall behind the unit should be of non-flammable material.
Provide the drive with the amount of fresh cooling air given in Installation
procedure.
Note: Very wide cabinet line-ups are delivered as “shipping splits”.
Required tools
The tools required for moving the unit to its final position, fastening it to the floor and
tightening the connections are listed below:
• crane, fork-lift or pallet truck (check load capacity!); iron bar, jack and rollers
• Pozidrive and Torx (2.5–6 mm) screwdrivers for the tightening of the frame
screws
• torque wrench
• set of wrenches or sockets for joining shipping splits.
42
Moving the unit
…by crane
Use the steel lifting lugs attached to the top of
the cabinet. Insert the lifting ropes or slings into
the holes of the lifting lugs.
The lifting lugs can be removed (not mandatory)
once the cabinet is in its final position. If the
lifting lugs are removed, the bolts must be
refastened to retain the degree of protection
of the cabinet.
IP54 units
Allowed minimum height of lifting ropes or slings
for IP54 units is 2 metres.
43
…by fork-lift or pallet truck
The center of gravity may be quite high. Be therefore careful

when transporting the unit. Tilting the cabinets must be
avoided.
The units are to be moved only in the upright position.
If using a pallet truck, check its load capacity before
attempting to move the unit.
…on rollers
(Not allowed with Marine versions)
Remove the wooden bottom frame which is part of

the shipment.
Lay the unit on the rollers and move it carefully until
close to its final location.
Remove the rollers by lifting the unit with a crane,
fork-lift, pallet truck or jack as described above.
Laying the unit on its back

If the cabinet needs to be laid on its back, it
must be supported from below beside the
Cabinet back panel Support cubicle seams as shown.
Notes:
• Transportation of a unit on its back is only
allowed if the unit is equipped for such
transportation at the factory.
• Never lay or transport a unit with sine filters
(ie, with option code +E206) on its back.
44
Final placement of the unit

The cabinet can be moved into its final position with an
iron bar and a wooden piece at the bottom edge of the
cabinet. Care is to be taken to properly place the
wooden piece so as not to damage the cabinet frame.
45
Before installation
Delivery check
The drive delivery contains:
• drive cabinet line-up
• optional modules (if ordered) installed into the control rack at the factory
• ramp for extracting supply and inverter modules from the cabinet
• hardware manual
• appropriate firmware manuals and guides
• optional module manuals
• delivery documents.
Check that there are no signs of damage. Before attempting installation and
operation, check the information on the type designation label of the drive to verify
that the unit is of the correct type. The label includes an IEC and NEMA rating, C-UL
US, and CSA markings, a type designation and a serial number, which allow
individual recognition of each unit. The first digit of the serial number refers to the
manufacturing plant. The next four digits refer to the unit’s manufacturing year and
week respectively. The remaining digits complete the serial number so that there are
no two units with the same serial number.
The following type designation label is located on the supply unit door.
In addition to the actual type designation label, there are the following two labels
attached elsewhere on the drive.
Each power module (ie, supply and inverter module) is also individually labelled.
46
Installation procedure
1 See detailed instructions in the following few
pages.
(1) The cabinet can be installed with its back
against a wall, or back-to-back with another unit.
Fasten the unit (or first shipping split) to the floor
A with fastening clamps or through the holes inside
A
the cabinet. See section Fastening the cabinet to
the floor (Non-marine units).
With marine versions, fasten the unit (or first
shipping split) to the floor and wall/roof as
described in section Fastening the unit to the floor
and wall (Marine units).
Note: A clearance of 400 mm minimum above the
basic roof level of the cabinet (see inset on left) is
Top clearances required for cooling.
> 320 mm (12.3”)
for fan replace- Note: Leave some space at the left-hand and
ment
right-hand sides of the line-up (A) to allow the
> 400 mm > 400 mm
(15.75”) (15.75”) doors to open sufficiently.
IP22/42 IP54
Note: Any height adjustment must be done before
fastening the units or shipping splits together.
Height adjustment can be done by using metal
shims between the bottom frame and floor.
2
(2) Remove the lifting bars (if present). In marine
units, also replace the lifting lugs with L-profiles
(see below). Use the original bolts to block any
unused holes.
(3) If the line-up consists of shipping splits, fasten
the first split to the second. Each shipping split
includes a joining cubicle where the busbars
connect to the next split.
(4) Fasten the second shipping split to the floor.
(5) Join the DC busbars and the PE busbars.
(6) Repeat steps (2) to (5) for the remaining
3 shipping splits.
47
Fastening the cabinet to the floor (Non-marine units)

The cabinet is to be fastened to the floor by using clamps along the edge of the
cabinet bottom, or by bolting the cabinet to the floor through the holes inside.
Clamping
Insert the clamps into the twin slots along the front and rear edges of the cabinet
frame body and fasten them to the floor with a bolt. The recommended maximum
distance between the clamps is 800 mm (31.5”).
If there is not enough working space behind the cabinet for mounting, replace the
lifting lugs at the top with L-brackets (not included) and fasten the top of the cabinet
to the wall.
Slot detail, front view

(dimensions in millimetres)
Clamp dimensions (in millimetres) Distances between slots
Cubicle Distance in millimetres and (inches)

Width
(mm)
Cabinet frame
300 150 (5.9”)
400 250 (9.85”)
Cabinet frame 600 450 (17.7”)
700 550 (21.65”)
800 650 (25.6”)
L-bracket
M16 screw
Cabinet top
Fastening the cabinet at the top with

L-brackets (side view)
48
Holes inside the cabinet

The cabinet can be fastened to the floor using the fastening holes inside the cabinet,
if they are accessible. The recommended maximum distance between the fastening
points is 800 mm (31.5”).
If there is not enough working space behind the cabinet for mounting, replace the
lifting lugs at the top with L-brackets (not included) and fasten the top of the cabinet
to the wall.
Fastening holes inside the

cabinet (marked with arrows)
L-bracket
M16 screw
25 mm (0.985”)
Cabinet top

L-brackets (side view)
Distances between fastening holes Added width:

Bolt size: M10 to M12 (3/8” to 1/2”). Side panels of the cabinet: 15 mm (0.6”)
Back panel of the cabinet: 10 mm (0.4”)
Cubicle Distance between holes Gap between cubicles (mm):
Width Outer
Ø31 mm (1.22”) IP 20 ... 42 IP 54
300 150 mm (5.9”)

400 250 (9.85”) ≈ 0.5 ≈1
(0.02”) (0.04”)
600 450 (17.7”)
700 550 (21.65”)
800 650 (25.6”)
49
Fastening the unit to the floor and wall (Marine units)

The unit must be fastened to the floor and roof (wall) as follows:
Bolt the unit to the floor through the holes in

1
each flat bar at the base of the cabinet using
M10 or M12 screws.
If there is not enough room behind the cabinet

2
for installation, clamp the rear ends of the flat
bars as shown in figure (2).
Fasten the top of the cabinet to the rear wall

3
and/or roof using brackets.
Use M10 or M12 screws; welding is not

recommended (see section Electric
welding below).
2 3
L-bracket
Back panel of M16 bolt
Clamps cabinet
Flat bars at base of cabinet Cabinet

Clamping the cabinet to the brackets (side view)
floor at the back
50
Joining the shipping splits

The busbar systems and wiring harnesses of two shipping splits are joined in the
common motor terminal cubicle (if present) or a busbar joining cubicle. Special M6
screws for fastening the shipping splits together are enclosed in a plastic bag inside
the rightmost cubicle of the first shipping split. The threaded bushings are already
mounted on the post.
Threaded bushing
Procedure
Maximum tightening torque:

5 Nm (3 ft.-lbs)
7 7
• Fasten the front post of the joining section with 7 screws to the front frame post of
the next cubicle.
51
• Remove any intermediate or partitioning plates covering the rear posts of the
joining cubicle.
Partitioning
plate
Busbar joining Intermediate plate Back posts accessible

cubicle
• Fasten the rear post of the joining section with seven screws (below the busbar
joining part) to the rear post of the next cubicle.
• Replace all partitioning plates in the upper part of it after connecting the DC
busbars (see section Connecting the DC busbars and the PE busbar).
Connecting the DC busbars and the PE busbar

Horizontal main DC busbars and the PE busbar are connected from the front of the
joining cubicle. All necessary materials are located in the joining cubicle.
• Remove the front metal partitioning plate located in the busbar joining cubicle.
• Unscrew the bolts of the joint pieces.
• Connect the busbars with the joint pieces (see figure below). For aluminium
busbars, suitable anti-oxidant joint compound must be used to avoid corrosion
and to ensure good electrical connection. The oxide layer must be scrubbed off
from the joints before applying the compound.
• Refit all shrouds for safety of personnel.
52
DC busbars
The DC busbar connection is shown below.
1 1 Joint pieces
1
1
Tighten the bolts to

55–70 Nm (40–50 ft.-lbs.)
Side view of single busbar connection
PE busbar
The PE busbar runs continuously through the line-up near the floor at the back. The
connection is shown below. No separate nuts are needed.
Top view PE busbar
Tighten the screws to

55–70 Nm (40–50 ft.-lbs.)
Shipping split A Shipping split B
53
Miscellaneous
Cable duct in the floor below the cabinet

A cable duct can be constructed below the 400 mm wide middle part of the cabinet.
The cabinet weight lies on the two 100 mm wide transverse sections which the floor
must carry.
Viewed from above Side view
With heavy
cabinets support
the structural C-
sections from
below.
This area can be used for a
cable duct
Prevent the cooling air flow

from the cable duct to the
cabinet by bottom plates.
To ensure the degree of
protection for the cabinet
use the original bottom Cables
plates delivered with the
unit. With user-defined
cable entries, take care of
the degree of protection, fire
protection and EMC
compliance.
54
Cooling air intake through bottom of cabinet

Units with air intake through the bottom of the cabinet (optional feature) are intended
for installation on an air duct in the floor. The required air inlets in the floor are as
listed below. Refer also to the dimensional drawings delivered with the unit.
• for Supply module cubicles: w × 505 mm, where w equals cubicle width – 50 mm
• for Inverter module cubicles, Auxiliary control cubicles, Incoming cubicles: w ×
400 mm, where w equals cubicle width – 50 mm
• w × 130 mm at the back of the cabinet line-up, where w equals the total width of
adjacent cubicles with air inlets. This area may or may not be consistent through
the width of the whole line-up.
Example
Supply module cubicle Incoming cubicle Inverter module cubicle Common motor
Cubicle width: 700 mm Cubicle width: 400 mm Cubicle width: 600 mm terminal cubicle
Air inlet size: Air inlet size: Air inlet size: (No air inlet required)
650 × 505 mm 350 × 400 mm 550 × 400 mm
Notes:
• The plinth of the cabinet must be supported all round.
• The air duct must be able to supply a sufficient volume of cooling air. The
minimum air flow values are given in the Technical data section of the Hardware
manual.
• The cubicles of diode supply units require a larger air inlet area than other
cubicles.
• Some cubicles (mainly those without active, heat-generating components) require
no air inlet.
55
Electric welding
It is not recommended to fasten the cabinet by welding.
Cabinets without flat bars at the base
• Connect the return conductor of the welding equipment to the cabinet frame at
the bottom within 0.5 metres of the welding point.
Cabinets with flat bars at the base
• Weld only the flat bar under the cabinet, never the cabinet frame itself.
• Clamp the welding electrode onto the flat bar about to be welded or onto the floor
within 0.5 metres of the welding point.
WARNING! If the welding return wire is connected improperly, the welding circuit
may damage electronic circuits in the cabinet. The thickness of the zinc coating of
the cabinet frame is 100 to 200 micrometers; on the flat bars the coating is
approximately 20 micrometers. Ensure that the welding fumes are not inhaled.
56
57

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

1. Select the motor according to the rating tables in chapter Technical Data. Use the
DriveSize PC tool if the default load cycles are not applicable.
2. Check that the motor ratings lie within the allowed ranges of the drive control
program:
•motor nominal voltage is 1/2 ... 2 · UN of the drive
•motor nominal current is 1/6 ... 2 · I2hd of the drive in DTC control and
0 ... 2 · I2hd in scalar control. The control mode is selected by a drive
parameter.
3. Check that the motor voltage rating meets the application requirements:
•The motor voltage is selected according to the AC voltage feeding the drive
when the drive is equipped with a diode input bridge (a non-regenerative drive)
and will operate in the motor mode (ie, no braking).
•The motor nominal voltage is selected according to “the equivalent AC power
source voltage of the drive” if the intermediate DC circuit voltage of the drive is
increased from the nominal level by resistor braking or by the control program
of a regenerative IGBT line side converter (parameter selectable function).
The equivalent AC power source voltage for the drive is calculated as follows:
UACeq = UDCmax/1.35
where
UACeq = equivalent AC power source voltage of the drive
UDCmax = maximum intermediate DC circuit voltage of the drive
See notes 6 and 7 below the Requirements table.

58
4. Consult the motor manufacturer before using a motor in a drive system where the
motor nominal voltage differs from the AC power source voltage.
5. Ensure that the motor insulation system withstands the maximum peak voltage in
the motor terminals. See the Requirements table below for the required motor
insulation system and drive filtering.
Example: When the supply voltage is 440 V and the drive is operating in the
motor mode only, the maximum peak voltage in the motor terminals can be
approximated as follows: 440 V · 1.35 · 2 = 1190 V. Check that the motor
insulation system withstands this voltage.
Protecting the motor insulation and bearings

The output of the drive comprises – regardless of output frequency – pulses of
approximately 1.35 times the equivalent mains network voltage with a very short rise
time. This is the case with all drives employing modern IGBT inverter technology.
The voltage of the pulses can be almost double at the motor terminals, depending on
the attenuation and reflection properties of the motor cable and the terminals. This in
turn can cause additional stress on the motor and motor cable insulation.
Modern variable speed drives with their fast rising voltage pulses and high switching
frequencies can cause current pulses that flow through the motor bearings, which
can gradually erode the bearing races and rolling elements.
The stress on motor insulation can be avoided by using optional ABB du/dt filters.
du/dt filters also reduce bearing currents.
To avoid damage to motor bearings, the cables must be selected and installed
according to the instructions given in this manual. In addition, insulated N-end (non-
driven end) bearings and output filters from ABB must be used according to the
following table. Two types of filters are used individually or in combinations:
• du/dt filtering (protects motor insulation system and reduces bearing currents).
• common mode filtering (CMF) (mainly reduces bearing currents).
Requirements table
The following table shows how to select the motor insulation system and when an
optional ABB du/dt filter, insulated N-end (non-driven end) motor bearings and ABB
common mode filters are required. The motor manufacturer should be consulted
regarding the construction of the motor insulation and additional requirements for
explosion-safe (EX) motors. Failure of the motor to fulfil the following requirements
or improper installation may shorten the life of the motor or damage the motor
bearings.

59
Motor type Nominal mains Requirement for

voltage (AC line
Motor insulation ABB du/dt filter, insulated N-end bearing and ABB common mode
voltage)
system filter
Manufacturer
PN < 100 kW 100 kW < PN < 350 kW PN > 350 kW

and or or
frame size < IEC 315 frame size > IEC 315 frame size > IEC 400
PN < 134 HP 134 HP < PN < 469 HP PN > 469 HP
and frame size or frame size or frame size
< NEMA 500 > NEMA 500 > NEMA 580
A Random- UN < 500 V Standard - +N + N + CMF
B wound M2_
500 V < UN < 600 V Standard + du/dt + du/dt + N + du/dt + N + CMF
B and M3_
or
Reinforced - +N + N + CMF
600 V < UN < 690 V Reinforced + du/dt + du/dt + N + du/dt + N + CMF
Form-wound 380 V < UN < 690 V Standard n.a. + N + CMF PN < 500 kW:
HX_ and AM_ + N + CMF
PN > 500 kW:
+ N + CMF + du/dt
Old* form- 380 V < UN < 690 V Check with the + du/dt with voltages over 500 V + N + CMF
wound HX_ motor
and modular manufacturer.
Random- 0 V < UN < 500 V Enamelled wire + N + CMF
wound HX_ with fibre glass
500 V < UN < 690 V + du/dt + N + CMF
and AM_ ** taping
N Random- UN < 420 V Standard: ÛLL = - + N or CMF + N + CMF
O wound and 1300 V
form-wound
N 420 V < UN < 500 V Standard: ÛLL = + du/dt + du/dt + N + du/dt + N + CMF
- 1300 V
or
A + du/dt + CMF
B
or
B
Reinforced: ÛLL = - + N or CMF + N + CMF
1600 V, 0.2 µs
rise time
500 V < UN < 600 V Reinforced: ÛLL = + du/dt + du/dt + N + du/dt + N + CMF
1600 V
or
+ du/dt + CMF
or
Reinforced: ÛLL = - + N or CMF + N + CMF
1800 V
600 V < UN < 690 V Reinforced: ÛLL = + du/dt + du/dt + N + du/dt + N + CMF
1800 V
Reinforced: ÛLL = - N + CMF N + CMF
2000 V, 0.3 µs
rise time ***
* manufactured before 1.1.1998

** For motors manufactured before 1.1.1998, check for additional instructions with the motor manufacturer.
*** If the intermediate DC circuit voltage of the drive will be increased from the nominal level by resistor braking or
by the IGBT supply unit control program (parameter selectable function), check with the motor manufacturer if
additional output filters are needed in the applied drive operation range.

60
Note 1: The abbreviations used in the table are defined below.
Abbreviation Definition
UN nominal voltage of the supply network
ÛLL peak line-to-line voltage at motor terminals which the motor insulation must withstand
PN motor nominal power
du/dt du/dt filtering at the output of the drive (option +E205)
CMF common mode filtering (option +E208)
N N-end bearing: insulated motor non-driven end bearing
n.a. Motors of this power range are not available as standard units. Consult the motor manufacturer.
Note 2: Explosion-safe (EX) motors

The motor manufacturer should be consulted regarding the construction of the motor insulation and
additional requirements for explosion-safe (EX) motors.
Note 3: High-output motors and IP 23 motors
For motors with higher rated output than what is stated for the particular frame size in EN 50347 (2001)
and for IP 23 motors, the requirements of ABB random-wound motor series M3AA, M3AP, M3BP are
given below. For other motor types, see the Requirements table above. Apply the requirements of
range “100 kW < PN < 350 kW” to motors with PN < 100 kW. Apply the requirements of range PN >
350 kW to motors within the range “100 kW < PN < 350 kW”. In other cases, consult the motor
manufacturer.
Manufacturer
Motor type Nominal mains Requirement for

voltage (AC line Motor insulation ABB du/dt filter, insulated N-end bearing and ABB common mode
voltage)
system filter
PN < 55 kW 55 kW < PN < 200 kW PN > 200 kW
PN < 74 HP 74 HP < PN < 268 HP PN > 268 HP
A Random- UN < 500 V Standard - +N + N + CMF

B wound M3AA, 500 V < UN < 600 V Standard + du/dt + du/dt + N + du/dt + N + CMF
M3AP, M3BP
B
or
Reinforced - +N + N + CMF
600 V < UN < 690 V Reinforced + du/dt + du/dt + N + du/dt + N + CMF
Note 4: HXR and AMA motors

All AMA machines (manufactured in Helsinki) for drive systems have form-wound windings. All HXR
machines manufactured in Helsinki starting 1.1.1998 have form-wound windings.
Note 5: ABB motors of types other than M2_, M3_, HX_ and AM_
Use the selection criteria given for non-ABB motors.
Note 6: Resistor braking of the drive
When the drive is in the braking mode for a large part of its operation time, the intermediate circuit DC
voltage of the drive increases, the effect being similar to increasing the supply voltage by up to 20
percent. The voltage increase should be taken into consideration when determining the motor
insulation requirement.
Example: Motor insulation requirement for a 400 V application must be selected as if the drive were
supplied with 480 V.
Note 7: Drives with an IGBT supply unit
If voltage is raised by the drive (this is a parameter selectable function for special applications only),
select the motor insulation system according to the increased intermediate circuit DC voltage level,
especially in the 500 V supply voltage range.

61
Note 8: Calculating the rise time and the peak line-to-line voltage
The peak line-to-line voltage at the motor terminals generated by the drive as well as the voltage rise
time depend on the cable length. The requirements for the motor insulation system given in the table
are “worst case” requirements covering installations with 30-metre and longer cables. The rise time can
be calculated as follows: t = 0.8 · ÛLL/(du/dt). Read ÛLL and du/dt from the diagram below. Multiply
the values of the graph by the supply voltage (UN). In case of drives with an IGBT supply unit or resistor
braking, the ÛLL and du/dt values are approximately 20% higher.
3.0
ÛLL/UN
2.5
2.0
1.5
du/dt
------------- (1/μs)
UN
1.0
0.5
0.0
100 200 300
Cable length (m)
With du/dt Filter
Note 9: Sine filters

Sine filters protect the motor insulation system. Therefore, a du/dt filter can be replaced with a sine
filter. The peak phase-to-phase voltage with a sine filter is approximately 1.5 × UN.
Permanent magnet synchronous motor

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

62
Thermal overload and short-circuit protection
Thermal overload protection of the drive and the input and motor cables
The drive protects itself and the input and motor cables against thermal overload
when the cables are dimensioned according to the nominal current of the drive. No
additional thermal protection devices are needed.
WARNING! If the drive is connected to multiple motors, a separate thermal overload

switch or a circuit breaker must be used for protecting each cable and motor. These
devices may require a separate fuse to cut off the short-circuit current.
Thermal overload protection of the motor

According to regulations, the motor must be protected against thermal overload and
the current must be switched off when overload is detected. The drive includes a
motor thermal protection function that protects the motor and switches off the current
when necessary. Depending on a drive parameter value, the function either monitors
a calculated temperature value (based on a motor thermal model) or an actual
temperature indication given by motor temperature sensors. The user can tune the
thermal model further by feeding in additional motor and load data.
See the Firmware manual of the drive application program for more information on
the motor thermal protection, and the connection and use of the temperature
sensors.
Protection against short-circuit in the motor cable

The drive protects the motor cable and the motor in a short-circuit situation when the
motor cable is dimensioned according to the nominal current of the drive. No
additional protection devices are needed.
Protection against short-circuit inside the drive or in the supply cable

• If the drive is equipped with internal AC fuses (option code +F260), install external
protection (such as fuses) at the supply to protect the input cable.
• If the drive is not equipped with AC input fuses, install external fuses at the supply
to protect the input cable and the drive. Use the AC fuse types listed in the
chapter Technical data on page 128, or equivalent fuses. Six fuses are needed for
each DSU module.
WARNING! Circuit breakers are not capable of providing sufficient protection

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

63
Ground fault protection

The inverter unit is equipped with an internal ground fault protective function to
protect the drive against ground faults in the drive, motor and motor cable (This is
not a personal safety or a fire protection feature). The ground fault protective
function can be disabled; refer to the Firmware Manual of the drive application
program.
See the ACS800 Ordering Information (3AFY64556568 [English], available on
request) for other available ground fault protection options.
The EMC filter (if present) includes capacitors connected between the main circuit
and the frame. These capacitors and long motor cables increase the ground leakage
current and may cause fault current circuit breakers to function.
Emergency stop devices

For safety reasons, install the emergency stop devices at each operator control
station and at other operating stations where emergency stop may be needed.
Pressing the stop key ( ) on the control panel of the drive, or turning the operating
switch of the drive from position “1” to “0” does not generate an emergency stop of
the motor or separate the drive from dangerous potential.
An emergency stop function is optionally available for stopping and switching off the
whole drive. Two modes are available: immediate removal of power (Category 0)
and controlled emergency stop (Category 1).
Note: If you add or modify the wiring in the drive safety circuits, ensure that the
appropriate standards (eg, IEC 61800-5-1, EN 62061, EN/ISO 13849-1 and -2) and
the ABB guidelines are met.
Restarting after an emergency stop

After an emergency stop, the emergency stop button must be released and a reset
performed before the main contactor (or main breaker) can be closed and the drive
started.

64
Prevention of unexpected start-up

The drive can be equipped with an optional Prevention of unexpected start-up
function according to standards IEC/EN 60204-1: 1997; ISO/DIS 14118: 2000 and
EN 1037: 1996. The circuit conforms to EN954-1, Category 3.
The function is achieved by disconnecting the control voltage to the power
semiconductors of the inverters of the drive. Thus it is not possible for the power
semiconductors to switch and generate the AC voltage needed to rotate the motor.
In case of faulty main circuit components, the DC voltage from the busbars can be
conducted to the motor but an AC motor cannot rotate without the field generated by
an AC voltage.
The operator activates the Prevention of unexpected start-up function using a switch
mounted on a control desk. When the function is activated, the switch is opened, and
an indicator lamp will light.
WARNING! The Prevention of unexpected start-up function does not disconnect the
voltage of the main and auxiliary circuits from the drive. Therefore maintenance work
on electrical parts of the drive can only be carried out after isolating the drive system
from the main supply.
Note: If a running drive is stopped by using the Prevention of unexpected start-up

function, the drive will cut off the motor supply voltage and the motor will coast to
stop.

65
Safe torque off

The drive supports the Safe torque off (STO) function according to standards
EN 61800-5-2: 2007; EN/ISO 13849-1: 2008, EN 60204-1: 2006; IEC 61508, EN
1037: 1995 + A1: 2008 and EN 62061: 2005. The function also corresponds to an
uncontrolled stop in accordance with category 0 of IEC 60204-1.
The Safe torque off function disables the control voltage of the power
semiconductors of the drive output stage, thus preventing the inverter from
generating the voltage required to rotate the motor (see the diagram below). By
using this function, short-time operations (like cleaning) and/or maintenance work on
non-electrical parts of the machinery can be performed without switching off the
power supply to the drive.
WARNING! The Safe torque off function does not disconnect the voltage of the main
and auxiliary circuits from the drive. Therefore maintenance work on electrical parts
of the drive or the motor can only be carried out after isolating the drive system from
the main supply.
Note: If a running drive is stopped by using the Safe torque off function, the drive will
cut off the motor supply voltage and the motor will coast to stop.
Note: If you add or modify the wiring in the drive safety circuits, ensure that the
appropriate standards (eg, IEC 61800-5-1, EN 62061, EN/ISO 13849-1 and -2) and
the ABB guidelines are met.

66
Selecting the power cables
General rules
Dimension the supply (input power) and motor cables according to local
regulations:
• The cable must be able to carry the drive load current. See chapter Technical
data for the rated currents.
• The cable must be rated for at least 70 °C maximum permissible temperature of
conductor in continuous use. For US, see Additional US requirements.
• The inductance and impedance of the PE conductor/cable (grounding wire) must
be rated according to permissible touch voltage appearing under fault conditions
(so that the fault point voltage will not rise excessively when an ground fault
occurs).
• 600 VAC cable is accepted for up to 500 VAC. For 690 VAC rated equipment, the
rated voltage between the conductors of the cable should be minimum 1 kV.
For drive frame size R5 and larger, or motors larger than 30 kW, symmetrical
shielded motor cable must be used (figure below). A four-conductor system can be
used up to frame size R4 with up to 30 kW motors, but shielded symmetrical motor
cable is recommended.
Note: When continuous conduit is employed, shielded cable is not required.
A four-conductor system is allowed for input cabling, but shielded symmetrical cable
is recommended. To operate as a protective conductor, the shield conductivity must
be as follows when the protective conductor is made of the same metal as the phase
conductors:
Cross-sectional area of the phase Minimum cross-sectional area of the
conductors corresponding protective conductor
S (mm2) Sp (mm2)
S < 16 S
16 < S < 35 16
35 < S S/2
Compared to a four-conductor system, the use of symmetrical shielded cable

reduces electromagnetic emission of the whole drive system as well as motor
bearing currents and wear.
Note: The cabinet configuration of the drive may require multiple supply and/or
motor cabling. Refer to the connection diagrams in Electrical installation.
The motor cable and its PE pigtail (twisted screen) should be kept as short as
possible in order to reduce electromagnetic emission as well as capacitive current.

67
Alternative power cable types

Power cable types that can be used with the drive are represented below.
Recommended
Symmetrical shielded cable: three phase conductors A separate PE conductor is required if the conductivity
and a concentric or otherwise symmetrically of the cable shield is < 50 % of the conductivity of the
constructed PE conductor, and a shield phase conductor.
PE conductor Shield
and shield Shield
PE
PE
PE Shield
A four-conductor system:
three phase conductors
and a protective
conductor.
Not allowed for motor cables Not allowed for motor cables with phase
conductor cross section larger than 10 mm2
(motors > 30 kW).
Motor cable shield

To effectively suppress radiated and conducted radio-frequency emissions, the
shield conductivity must be at least 1/10 of the phase conductor conductivity. The
requirements are easily met with a copper or aluminium shield. The minimum
requirement of the motor cable shield of the drive is shown below. It consists of a
concentric layer of copper wires with an open helix of copper tape. The better and
tighter the shield, the lower the emission level and the bearing currents.
Copper wire screen Helix of copper tape Inner insulation

Insulation jacket
Cable core
Additional US requirements
Type MC continuous corrugated aluminum armor cable with symmetrical grounds or
shielded power cable must be used for the motor cables if metallic conduit is not
used. For the North American market, 600 VAC cable is accepted for up to 500 VAC.
1000 VAC cable is required above 500 VAC (below 600 VAC). For drives rated over
100 amperes, the power cables must be rated for 75 °C (167 °F).

68
Conduit
Where conduits must be coupled together, bridge the joint with a ground conductor
bonded to the conduit on each side of the joint. Bond the conduits also to the drive
enclosure. Use separate conduits for input power, motor, brake resistors, and control
wiring. When conduit is employed, type MC continuous corrugated aluminum armor
cable or shielded cable is not required. A dedicated ground cable is always required.
WARNING! Do not run motor wiring from more than one drive in the same conduit.
Armored cable / shielded power cable

The motor cables can be run in the same cable tray as other 460 V or 600 V power
wiring. Control and signal cables must not be run in the same tray as power cables.
Six conductor (3 phases and 3 ground) type MC continuous corrugated aluminum
armor cable with symmetrical grounds is available from the following suppliers (trade
names in parentheses):
• Anixter Wire & Cable (Philsheath)
• BICC General Corp (Philsheath)
• Rockbestos Co. (Gardex)
• Oaknite (CLX).
Shielded power cables are available from Belden, LAPPKABEL (ÖLFLEX) and
Pirelli, among others.

69
Power factor compensation capacitors

Power factor compensation is not needed with AC drives. However, if a drive is to be
connected to a system with compensation capacitors already installed, note the
following restrictions.
WARNING! Do not connect power factor compensation capacitors to the motor

cables (between the drive and the motor). They are not meant to be used with AC
drives and can cause permanent damage to the drive or themselves.
If there are power factor compensation capacitors in parallel with the three-phase
input of the drive:
• Do not connect a high-power capacitor to the power line while the drive is
connected. The connection will cause voltage transients that may trip or even
damage the drive.
• If capacitor load is increased/decreased step by step when the AC drive is
connected to the power line, ensure that the connection steps are low enough not
to cause voltage transients that would trip the drive.
• Check that the power factor compensation unit is suitable for use in systems with
AC drives, ie, harmonic-generating loads. In such systems, the compensation unit
should typically be equipped with a blocking reactor or harmonic filter.
Equipment connected to the motor cable
Installation of safety switches, contactors, connection boxes, etc

To minimize the emission level when safety switches, contactors, connection boxes
or similar equipment are installed in the motor cable between the drive and the
motor:
• EU: Install the equipment in a metal enclosure with 360 degrees grounding for the
shields of both the incoming and outgoing cables, or in another way connect the
shields of the cables together.
• US: Install the equipment in a metal enclosure in a way that the conduit or motor
cable shielding runs consistently without breaks from the drive to the motor.
Bypass connection
WARNING! Never connect the supply power to the drive output terminals U2, V2
and W2. If frequent bypassing is required, employ mechanically connected switches
or contactors. Mains (line) voltage applied to the output can result in permanent
damage to the unit.

70
Before opening an output contactor (in the DTC motor control mode)
Stop the drive and wait for the motor to stop before opening a contactor between the
output of the drive and the motor when the DTC control mode is selected. (See the
Firmware Manual of the drive appliction program for the required parameter
settings.) Otherwise, the contactor will be damaged.
In scalar control, the contactor can be opened with the drive running.
Relay output contacts and inductive loads

Inductive loads (such as relays, contactors, motors) cause voltage transients when
switched off.
The relay contacts of the RMIO board are protected with varistors (250 V) against
overvoltage peaks. In spite of this, it is highly recommended to equip inductive loads
with noise attenuating circuits (varistors, RC filters [AC] or diodes [DC]) to minimize
the EMC emission at switch-off. If not suppressed, the disturbances may connect
capacitively or inductively to other conductors in the control cable and form a risk of
malfunction in other parts of the system.
Install the protective component as close to the inductive load as possible. Do not
install the protective components at the terminal block.
Relay outputs
Varistor
RO (NC)
RO (C)
230 VAC
RO (NO)
RC filter
RO (NC)
230 VAC RO (C)
RO (NO)
Diode
RO (NC)
24 VDC RO (C)
RO (NO)

71
Selecting the control cables

All control cables must be shielded.
Use a double-shielded twisted pair cable (see figure a) for analogue signals. This
type of cable is recommended for the pulse encoder signals also. Employ one
individually shielded pair for each signal. Do not use common return for different
analogue signals.
A double-shielded cable is the best alternative for low-voltage digital signals but
single-shielded twisted multipair cable (figure b) is also usable.
a b
Double-shielded twisted Single-shielded twisted
pair cable pair cable
Run analogue and digital signals in separate, shielded cables.

Relay-controlled signals, providing their voltage does not exceed 48 V, can be run in
the same cables as digital input signals. It is recommended that the relay-controlled
signals be run as twisted pairs.
Never mix 24 VDC and 115 / 230 VAC signals in the same cable.
Relay cable
The cable type with braided metallic screen (eg, ÖLFLEX LAPPKABEL, Germany)
has been tested and approved by ABB.
Control panel cable

In remote use, the cable connecting the control panel to the drive must not exceed 3
metres (10 ft). The cable type tested and approved by ABB is used in control panel
option kits.
Coaxial cable (for use with Advant Controllers AC 80/AC 800)

• 75 ohm
• RG59, diameter 7 mm or RG11, diameter 11 mm
• Maximum cable length: 300 m (1000 ft)

72
Connection of a motor temperature sensor to the drive I/O
WARNING! IEC 60664 requires double or reinforced insulation between live parts
and the surface of accessible parts of electrical equipment which are either non-
conductive or conductive but not connected to the protective earth.
To fulfil this requirement, the connection of a thermistor (and other similar
components) to the digital inputs of the drive can be implemented in three alternate
ways:
1. There is double or reinforced insulation between the thermistor and live parts of
the motor.
2. Circuits connected to all digital and analogue inputs of the drive are protected
against contact and insulated with basic insulation (the same voltage level as the
drive main circuit) from other low voltage circuits.
3. An external thermistor relay is used. The insulation of the relay must be rated for
the same voltage level as the main circuit of the drive. For connection, see the
Firmware Manual of the drive application program.
Installation sites above 2000 metres (6562 feet)
WARNING! Protect against direct contact when installing, operating and servicing
the RMIO board wiring and optional modules attached to the board. The Protective
Extra Low Voltage (PELV) requirements stated in EN 50178 are not fulfilled at
altitudes above 2000 m (6562 ft).

73
Routing the cables

Route the motor cable away from other cable routes. Motor cables of several drives
can be run in parallel installed next to each other. It is recommended that the motor
cable, input power cable and control cables be installed on separate trays. Avoid
long parallel runs of motor cables with other cables in order to decrease
electromagnetic interference caused by the rapid changes in the drive output
voltage.
Where control cables must cross power cables make sure they are arranged at an
angle as near to 90 degrees as possible. Do not run extra cables through the drive.
The cable trays must have good electrical bonding to each other and to the
grounding electrodes. Aluminium tray systems can be used to improve local
equalizing of potential.
A diagram of the cable routing is below.
Motor cable
Drive
min 300 mm (12 in.)
Power cable
Input power cable Motor cable
min 200 mm (8 in.) 90 ¬ min 500 mm (20 in.)
Control cables
Control cable ducts

24 V 230/120 V 24 V 230/120 V
Not allowed unless the 24 V Lead 24 V and 230/120 V control

cable is insulated for 230/120 V cables in separate ducts inside
or insulated with insulation the cabinet.
sleeving for 230/120 V.

74

75

This chapter describes the electrical installation procedure of the drive.
WARNING! Only qualified electricians are allowed to carry out the work described in
this chapter. Follow the Safety instructions on the first pages of this manual. Ignoring
the safety instructions can cause injury or death.
WARNING! During the installation procedure, the supply and inverter modules may
have to be temporarily extracted from the cabinet. The modules are heavy, and have
a high center of gravity. To minimize the danger of toppling over, keep the sheet
metal support supplied with the drive attached to the modules whenever
manoeuvring them outside the cabinet.
Before installation
Checking the insulation of the assembly

Every drive has been tested for insulation between the main circuit and the chassis
(2500 V rms 50 Hz for 1 second) at the factory. Therefore, do not make any voltage
tolerance or insulation resistance tests (eg, hi-pot or megger) on any part of the
drive. When checking the insulation of the assembly, proceed in the following
manner:
WARNING! Check the insulation before connecting the drive to the supply. Make
sure that the drive is disconnected from the supply (input power).
Drive
Do not make any voltage tolerance or insulation resistance tests (eg, hi-pot or
megger) on any part of the drive as testing can damage the drive. Every drive has
been tested for insulation between the main circuit and the chassis at the factory.
Also, there are voltage-limiting circuits inside the drive which cut down the testing
voltage automatically.
Supply cable
Check the insulation of the supply (input) cable according to local regulations before
connecting to the drive.
76
Motor and motor cable

Check the insulation of the motor and motor cable as follows:
1. Check that the motor cable is connected to the motor, and disconnected from the
drive output terminals U2, V2 and W2.
2. Measure the insulation resistance between each phase conductor and the
protective earth conductor using a measuring voltage of 500 V DC. The insulation
resistance of an ABB motor must exceed 100 Mohm (reference value at 25 °C or
77 °F). For the insulation resistance of other motors, please consult the
manufacturer’s instructions.
Note: Moisture inside the motor casing will reduce the insulation resistance. If
moisture is suspected, dry the motor and repeat the measurement.
U1
M
V1
3~
ohm W1
PE
IT (ungrounded) systems
An EMC filter (option +E202) is not suitable for use in an IT (ungrounded) system. If
the drive is equipped with an EMC filter (option +E202), disconnect the filter before
connecting the drive to the supply network. For detailed instructions on how to do
this, please contact your local ABB representative.
WARNING! If a drive with an EMC filter (option +E202) is installed on an IT system

[an ungrounded power system or a high resistance-grounded (over 30 ohms) power
system], the system will be connected to ground potential through the EMC filter
capacitors of the drive. This may cause danger or damage the unit.
External earth fault in IT (ungrounded) systems

On ungrounded systems, an optional insulation monitoring device (Bender IRDH265
or IRDH275, option +Q954) is used. Refer to its documentation for set-up
instructions.
77
Input power connection – Units without main switch-disconnector

or main breaker (no option +F253 or +F255)
Connection diagrams
Six-pulse connection, two DSU modules in parallel
PE PE
L11
L21
L31
L12 *)
L22
L32
L1
L2
L3
L11
L21
L31
*)
L12
L22
L32
Notes:
• No parallel cabling is shown here.
• Each input terminal of the supply modules must be fed through a dedicated fuse. The fuses are specified in Technical
data.
*) Contactors are optional.
78
Twelve-pulse connection, two DSU modules in parallel

PE PE
L11
L21
L31
*)
L12
L1 L22
L2 L32
L3
L1
L2
L3
L11
L21
L31
*)
L12
L22
L32
Notes:
• No parallel cabling (for each module) is shown here.
It is also possible to connect all input power terminals of module 1 to the transformer Y-output and module 2 to the
transformer D-output. Note, however, that then the two bridges inside a single module do not form a 12-pulse
connection any more. This means that the benefits of the 12-pulse connection are not available during a temporary
operation with one module out of use (eg, for maintenance).
• Each input terminal of the supply modules must be fed through a dedicated fuse. The fuses are specified in Technical
data.
• The secondaries of the transformer must not be grounded.
• When the same 12-pulse transformer is used to supply more than one module, connect the DC outputs of all modules
to a common DC link. Separate links will cause current unbalance fault trips due to circulating currents between the
modules.
*) Contactors are optional.
79
Connection procedure
WARNING! Read and follow the instructions given in Safety instructions. Ignoring
the instructions can cause physical injury or death, or damage to the equipment.
WARNING! The supply modules are heavy and have a high center of gravity. Be
careful when manoeuvring the modules.
Phase I – Removing the module

To remove the module, follow the steps below:
E E
A E
G G
1. Turn the main switch-disconnector to the open position. (A)

2. Release the door handle and open the doors. (B)
80
3. Disconnect the module signal wire set. (C) The counterpart must be used and
connected to the wire set instead of the DSU module, when the module is
removed from the cabinet.
4. Unplug also the pair of fibre optic cables from its connectors on the front of the
DSU module. Bind the fibre optic cables to a suitable support (away from the
area you are working in) without twisting or coiling them. The cables must not be
squeezed between any objects. (D)
5. Loosen the module fastening screws and the quick connector locking screw (5-
mm hexagonal head). (E) If your drive has the marine construction (option
+C121), remove the fan. For instructions, see Replacing the fan of the supply
module on page 115. Then loosen also the two bolts that connect the bottom of
the module to the installation plate at the back.
6. Place the module pull-out ramp firmly against the cabinet base. (F) Insert the
module pull-out ramp under the two screws on the base of the cabinet and
tighten. (G)
81
7. Pull the module carefully out of the cabinet along the ramp. (H)
G G
Phase 2 – Installing the cables

1. Remove the plastic insulators covering the input power terminals.
82
2. Lead the cables into the inside of the cabinet. Make the 360° grounding
arrangement at the cable entries as shown below.
Grommet (in
IP54 units only)
3. Connect the cables as follows:

- Twist the cable shields to bundles and connect to the cabinet PE (ground)
busbar. Connect the separate ground conductors/cables to the cabinet PE
(ground) busbar.
- Connect the phase conductors to the input power terminals (U1.1 …).
Depending on the cable size, use cable lugs or the dual-cable screw lug
connectors which are installed to the busbars as standard. For details on the
terminals and tightening torques, see Technical data – Input power connection
on page 130, and section Use of the dual-cable screw lug connector below.
4. Refit the plastic insulators onto the input power terminals.
Phase 3 – Replacing the module
1. Push the module back in – mind your fingers – and tighten the fastening screws.
2. Tighten the connector locking screw to 4 Nm (3 lbf.ft). Be careful not to break the
locking screw. Note that the module can only mate with the quick connector
when the switch-disconnector is in the open position.
3. Plug the module signal wire set to the module signal connector.
4. Plug the fibre optic cables back to their connectors.
5. Remove the module pull-out ramp and close the cabinet doors.
83
Use of the dual-cable screw lug connector
1
2
3
Removal of the dual-cable screw lug connector
84
Input power connection – Units with main switch-disconnector

or main breaker (option +F253 or +F255)
Connection diagrams
Six-pulse connection, two DSU modules in parallel
PE PE
*) 1L1
L1 Switching,
1L2
L2 breaking,
1L3 disconnecting
L3
and grounding
**) devices
Incoming cubicle
Supply module cubicle

Notes:
*)
Fuses are not required if the input power line is constructed of busbars that withstand the transformer short circuit current,
or the input cables will be protected by some other means, eg, by a circuit breaker at the primary side of the transformer.
**)
The cable lead-through details (number and size of holes), and cable connection details (number and dimensions of
busbars, tightening torque) are given in chapter Technical data, section Input power connection.
85
Twelve-pulse connection, two DSU modules in parallel
PE PE
*) 1L1 Switching, breaking,
disconnecting and
1L2
grounding devices
1L3
2L1
Switching, breaking,
2L2 disconnecting and
2L3 grounding devices
**)
Incoming cubicle
Supply module cubicle
Notes:
When the same 12-pulse transformer is used to supply more than one module, connect the DC outputs of all modules to a
common DC link. Separate links will cause current unbalance fault trips due to circulating currents between the modules.
*)
Fuses are not required if the input power line is constructed of busbars that withstand the transformer short circuit current,
or the input cables will be protected by some other means, eg, by a circuit breaker at the primary side of the transformer.
**)
No bridging (connecting 1L1 to 2L1, 1L2 to 2L2, and 1L3 to 2L3) is allowed!
There are two separate incoming cubicles – one for terminals 1L1, 1L2 and 1L3, the other for 2L1, 2L2 and 2L3 – if
a) the unit is equipped with main breakers, b) the drive is UL listed, or c) the incoming cubicle is designed for a busbar
connection.
The cable lead-through details (number and size of holes), and cable connection details (number and dimensions of
busbars, tightening torque) are given in chapter Technical data, section Input power connection.
86
WARNING! Read and follow the instructions given in Safety instructions. Ignoring
Open the door of the incoming (main switch-disconnector or main breaker) cubicle.
Remove any shrouds covering the input terminals and cable entries.
Lead the cables into the cubicle. Make the 360° grounding arrangement at the cable entries as shown
below.
Grommet (in IP54

units only)
Cut the cables to suitable length.
Strip the cables and conductors.
Twist the cable screens into bundles and connect to the cabinet PE (ground) busbar.
Connect the separate ground conductors/cables to the cabinet PE (ground) busbar.
Connect the phase conductors to the input terminals using the torques given in chapter Technical data,
section Input power connection.
Refit the shrouds removed earlier.
Close the door.
87
Motor connection – Units without common motor terminal cubicle (no

option +H359)
The motor cables are to be connected to the output busbars behind each inverter
module. The location and dimensions of the busbars are visible in the dimensional
drawings delivered with the drive, as well as the example drawings presented in
chapter Dimensions.
Connection diagram
The diagram below shows a drive with a single inverter module. 360° grounding is to
be used at cable entries.
PE
U2
V2
U1
V1
M
W2
W1 3~
PE
Inverter module cubicle
The recommended cable types are given in chapter Planning the electrical installation.
Whenever the inverter unit consists of parallel-connected inverter modules, all the
modules (two are shown below) are to be cabled separately to the motor.
PE
U2
V2
W2
U1
V1
M
W1 3~
U2 PE
V2
W2
88
WARNING! The cabling from all inverter modules to the motor must be physically
identical considering cable type, cross-sectional area, and length.
PE
U2
V2
W2
U1
V1
M
W1 3~
U2 PE
V2
W2
89
WARNING! Read and follow the instructions given in Safety instructions. Ignoring the instructions
can cause physical injury or death, or damage to the equipment.
WARNING! The supply modules are heavy and have a high center of gravity. Be careful when
manoeuvring the modules. To minimize the danger of toppling over, keep the support legs of the
modules extended whenever manoeuvring the modules outside the cabinet.
Extract each inverter module from the cubicle as follows:

(1) Open the door of the inverter module cubicle.
(2) Remove the shroud covering the upper part of the cubicle.
(3) Open the transparent cover on the front of the inverter module and disconnect the fibre optic cables.
Move the cables aside.
(4) Remove the L-shaped DC busbars on top of the module.
(5) Disconnect the terminal block (X50) next to the DC busbars.
(6) Remove the two module fastening screws (6a) at the top. At the base of the module, loosen the two
fastening screws (6b) but leave them in place; lift the bracket (6c) into the up position.
(7) Insert the module pull-out ramp under the two screws at the base of the module and tighten.
(8) Pull the module carefully out of the cubicle along the ramp. Make sure the wires do not catch.
(9) Extend the support legs of the module. Keep the legs extended until the module is about to be inserted
back into the cubicle.
6a
4
3
8
6c
9a 9b
6b
90
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)
Cut the cables to suitable length.
Strip the cables and conductors.
Twist the cable screens into bundles and connect to cabinet PE (ground) busbar.
Connect any separate ground conductors/cables to cabinet PE (ground) busbar.
Connect the phase conductors to the output terminals.
Use the tightening torques specified in Technical data – Motor connection on page 132.
Insert each inverter module into the cubicle as follows:

(1) Move the inverter module close to the ramp, then retract the support legs of the module.
(2) Push the module back into the cubicle – mind your fingers.
(3) Refasten the module fixing screws at the top, reconnect the DC busbars.
(4) Reconnect the cables (X50, fibre optic cables).
(5) Loosen the module fastening screws at the base of the module and remove the pull-out ramp. Flip the
module fastening bracket into the down position and tighten the screws.
Close the doors.
At the motor, connect the cables according to instructions from the motor manufacturer. Pay special
attention to the phase order.
For minimum radio frequency interference:
• ground the cable shield 360 degrees at the lead-through of the motor terminal box
360 degrees grounding
Conductive gaskets
• or ground the cable by twisting the shield as follows: flattened width > 1/5 × length.
b > 1/5 x a
b
a
91
Motor connection – Units with common motor terminal cubicle

(option +H359)
Connection diagram
PE
U2
V2
U1
V1
M
W2
W1 3~
PE
Inverter module cubicle Common motor terminal

cubicle
See the connection procedure on page 90.
92
Control connections
Drive/inverter control connections

The control connections are made on the terminal blocks provided in the swing-out
frame in the auxiliary control cubicle of the drive. Refer to the circuit diagrams
delivered with the drive, and to the chapter Motor control and I/O board (RMIO).
Supply unit control connections

The supply unit is controlled using the local control devices mounted on the cabinet
door. No external control connections by the user are needed. However, the user
can connect certain external devices to the supply module. It is possible to:
• halt the supply unit by an external emergency stop button (if the unit is equipped
with a local emergency stop button)
• read supply unit’s status information through the relay outputs.
Refer to the circuit diagrams delivered with the drive for the connection terminals for
the external control devices.
93
Turn the main switch-disconnector into open position (or rack the withdrawable main breaker out).
Release the door handle and open the door of the auxiliary control cubicle.
Remove the two locking screws at the edge of the swing-out frame and open the frame.
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.
Run the cables between the EMI conductive cushions as shown below. Strip the cable at this location to
enable proper connection of the bare shield and the cushions. Tighten the cushions firmly onto the cable
shields.
Side view
Strain relief EMI conductive
cushions
Grommet Lead-through plate
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).
Stripped cable Conductive surface of Stripped part covered

the shield exposed with copper foil
Copper foil
Cable shield Shielded twisted pair
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
Thickest cable Thinnest cable
94
Run the cables to the swing-out frame as shown below. Wherever possible, use the existing cable trunking
(1) in the cabinet. Use sleeving wherever the cables are laid against sharp edges. Leave some slack in the
cable at the hinge (2) to allow the frame to open fully. Tie the cables to the braces (3) to provide strain
relief.
Swing-out frame open Cable routing example
3
1
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.
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).
Close the swing-out frame, refasten, and close the doors.
95
Installation of optional modules and PC

The optional module (such as fieldbus adapter, I/O extension module and the pulse
encoder interface) is inserted into the optional module slot of the inverter unit control
board (RDCU) and fixed with two screws. See the appropriate optional module
manual for further instructions.
Cabling of I/O and fieldbus modules
Module
Keep unshielded portion as
short as possible
Shield
1
2
3
4
To nearest PE terminal
Cabling of pulse encoder interface module
CHASSIS
Note 1: If the encoder is of unisolated

RTAC-01
PULSE ENCODER INTERFACE
GND
12345678 123456
SHLD
F01
type, ground the encoder cable at the
AB E
23 6
SHLD
CD
45
789
CHA
drive end only. If the encoder is

CHA+
CHB
CHA-
X2
Keep unshielded portion as
WD/
galvanically isolated from the motor

CHB+
INIT
CHB-
NODE ID
short as possible CHZ+
CHZ- shaft and the stator frame, ground the

0V
0V
encoder cable shield at the drive and
the encoder end.
1
2
3
4
V OUT
+15V
X1
V IN
+24V
Note 2: Twist the pair cable wires.
Fibre optic link

A DDCS fibre optic link is provided via the RDCO optional module for PC tools,
master/follower link, NDIO, NTAC, NAIO, AIMA I/O module adapter and fieldbus
adapter modules of type Nxxx. See RDCO User’s Manual [3AFE 64492209
(English)] for the connections. Observe colour coding when installing fibre optic
cables. Blue connectors go to blue terminals, and grey connectors to grey terminals.
When installing multiple modules on the same channel, connect them in a ring.
96
Connections and tap settings of the auxiliary voltage transformer

of the drive
3~ Input
Primary
Secondary
Output
3~ input 1~ output 3~ output
Supply Tap settings Supply 230 V 400 V (50 Hz) 320 V (60 Hz)
Terminals
voltage A1 to... B1 to… C1 to… voltage Terminals Tap setting Terminals Terminals
690 V A1, B1, C1 C2 A2 B2 690 V a3, n1 230– a1, b1, c1 a2, b2, c2
660 V A1, B1, C1 C2 A2 B2 660 V a3, n1 230+ a1, b1, c1 a2, b2, c2
97
Switching on and selecting the supply voltage of the auxiliary

voltage transformer of the DSU module
1. Detach the lid which covers the switches and selector of the auxiliary voltage
transformer of the DSU module. The lid is on the front cover of the module.
In the figure below, the lid has been detached already.
2. Check that the secondary circuit is closed, that is, check that the grounding
switch (A) is pressed down. See the figure below.
3. Close the protective circuit breaker (B) of the auxiliary voltage transformer, that
is, set it to the ON position.
4. Select the primary side voltage of the transformer by attaching the plug (C) to
the appropriate position.
5. Repeat this procedure with all diode supply modules.
Installation of brake resistors

A drive with option +D150 (brake copper) and option +D151 (brake resistor) have
both the chopper the brake resistor installed as standard. No installation by the
customer is needed. However, if the drive is equipped with option +D150 only, the
user must acquire and install the brake resistors according to the instructions in
chapter Resistor braking.
98
99

This chapter shows
• external control connections to the control board of the inverter unit with the
ACS800 standard control program (Factory macro)
• specifications of the inputs and outputs of the board.
Note: This chapter describes the standard I/O connections of the RMIO board
controlling the inverter unit. There is also another RMIO board which controls the
supply unit. The supply unit I/O connections are reserved for internal use (no
customer connections are possible or allowed). See chapter Hardware description
for the description of the supply unit I/O interface.
Note on cabinet-installed ACS800 drives

The terminals of the RMIO board are optionally wired to terminal block X2. The
connections shown below apply also to terminal block X2 (the markings are identical
to the ones on the RMIO board).
Terminals of X2 accept cables from 0.5 to 4.0 mm2 (22 to 12 AWG). The tightening
torque for screw terminals is 0.4 to 0.8 Nm (0.3 to 0.6 lbf.ft). For disconnecting wires
from spring terminals, use a screwdriver with a blade thickness of 0.6 mm (0.024”)
and width of 3.5 mm (0.138”), for example Phoenix Contact SZF 1-0,6X3,5.
Note on the terminal labelling

Optional modules (type Rxxx) may have terminal designations that coincide with
those of the RMIO board.

100
External control connections (non-US)

External control cable connections to the RMIO board for the ACS800 drive control
program (Factory macro) are shown below. For external control connections of other
application macros and programs, see the appropriate Firmware manual of the drive
application program.
X20
Terminal block size: 1 VREF- Reference voltage -10 VDC, 1 kohm < RL <
cables 0.3 to 3.3 mm2 (22 to 12 AWG) 2 AGND 10 kohm
0.2 to 0.4 Nm (0.2 to 0.3 lbf ft) 1 VREF+ Reference voltage 10 VDC, 1 kohm < RL <
2 AGND 10 kohm
3 AI1+ Speed reference 0(2) ... 10 V, Rin >
4 AI1- 200 kohm
5 AI2+ By default, not in use. 0(4) ... 20 mA, Rin =
6 AI2- 100 ohm
8 AI3- 100 ohm
rpm 9 AO1+ Motor speed 0(4) ... 20 mA = 0 ... motor
10 AO1- nom. speed, RL < 700 ohm
A 11 AO2+ Output current 0(4) ... 20 mA = 0 ... motor
12 AO2- nom. current, RL < 700 ohm
X22
1 DI1 Stop/Start
1) Only effective if par. 10.03 is set to 2 DI2 Forward/Reverse 1)
REQUEST by the user. 3 DI3 Not in use
4 DI4 Acceleration & deceleration select 2)
2) 0 = open, 1 = closed 5 DI5 Constant speed select 3)
DI4 Ramp times according to 6 DI6 Constant speed select 3)
0 parameters 22.02 and 22.03 7 +24VD +24 VDC max. 100 mA
1 parameters 22.04 and 22.05 8 +24VD
9 DGND1 Digital ground
3)
See par. group 12 CONSTANT
SPEEDS.
11 DIIL Start interlock (0 = stop) 4)
DI5 DI6 Operation
0 0 Set speed through AI1
X23
1 0 Constant speed 1 1 +24V Auxiliary voltage output and input, non-
0 1 Constant speed 2 2 GND isolated, 24 VDC 250 mA 5)
1 1 Constant speed 3 X25
1 RO1 Relay output 1: ready
4) See parameter 21.09 START INTRL 2 RO1
FUNC. 3 RO1
5) Total maximum current shared
X26
between this output and optional
modules installed on the board. 1 RO2 Relay output 2: running
2 RO2
3 RO2
X27
1 RO3 Relay output 3: fault (-1)
Fault 2 RO3
3 RO3

101
External control connections (US)

External control cable connections to the RMIO board for the ACS800 drive control
program (Factory macro US version) are shown below. For external control
connections of other application macros and programs, see the appropriate
Firmware manual of the drive application program.
X20
Terminal block size: 1 VREF- Reference voltage -10 VDC, 1 kohm < RL <
cables 0.3 to 3.3 mm2 (22 to 12 AWG) 2 AGND 10 kohm
0.2 to 0.4 Nm (0.2 to 0.3 lbf ft) 1 VREF+ Reference voltage 10 VDC, 1 kohm < RL <
2 AGND 10 kohm
3 AI1+ Speed reference 0(2) ... 10 V, Rin >
4 AI1- 200 kohm
6 AI2- 100 ohm
8 AI3- 100 ohm
rpm 9 AO1+ Motor speed 0(4) ... 20 mA = 0 ... motor
10 AO1- nom. speed, RL < 700 ohm
A 11 AO2+ Output current 0(4) ... 20 mA = 0 ... motor
12 AO2- nom. current, RL < 700 ohm
X22
1 DI1 Start ( )
1) Only effective if par. 10.03 is set to 2 DI2 Stop ( )
REQUEST by the user. 3 DI3 Forward/Reverse 1)
4 DI4 Acceleration & deceleration select 2)
2) 0 = open, 1 = closed 5 DI5 Constant speed select 3)
DI4 Ramp times according to 6 DI6 Constant speed select 3)
0 parameters 22.02 and 22.03 7 +24VD +24 VDC max. 100 mA
1 parameters 22.04 and 22.05 8 +24VD
3)
See par. group 12 CONSTANT
SPEEDS.
11 DIIL Start interlock (0 = stop) 4)
DI5 DI6 Operation
0 0 Set speed through AI1
X23
1 0 Constant speed 1 1 +24V Auxiliary voltage output and input, non-
0 1 Constant speed 2 2 GND isolated, 24 VDC 250 mA 5)
1 1 Constant speed 3 X25
1 RO1 Relay output 1: ready
4) See parameter 21.09 START INTRL 2 RO1
FUNC. 3 RO1
5) Total maximum current shared
X26
between this output and optional
modules installed on the board. 1 RO2 Relay output 2: running
2 RO2
3 RO2
X27
1 RO3 Relay output 3: fault (-1)
Fault 2 RO3
3 RO3

102
RMIO board specifications

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

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

Voltage 24 VDC ± 10%, short circuit proof
Maximum current 250 mA (shared between this output and optional modules installed on the RMIO)
Analogue outputs
Two programmable current outputs: 0 (4) to 20 mA, RL < 700 ohm
Resolution 0.1% (10 bit)
Inaccuracy ± 1% (Full Scale Range) at 25 °C (77 °F). Temperature coefficient: ± 200 ppm/°C
(± 111 ppm/°F) max.
Digital inputs
With the drive control program six programmable digital inputs (common ground: 24
VDC, -15% to +20%) and a start interlock input. Group isolated, can be divided in two
isolated groups (see Isolation and grounding diagram below).
Thermistor input: 5 mA, < 1.5 kohm “1” (normal temperature), > 4 kohm “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

103
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
DDCS fibre optic link

With optional communication adapter module RDCO. Protocol: DDCS (ABB
Distributed Drives Communication System)
24 VDC power input
Voltage 24 VDC ± 10%
Typical current consumption 250 mA
(without optional modules)
Maximum current consumption 1200 mA (with optional modules inserted)
The terminals on the RMIO board as well as on the optional modules attachable to the board fulfil the Protective Extra
Low Voltage (PELV) requirements stated in EN 50178 provided that the external circuits connected to the terminals also
fulfil the requirements and the installation site is below 2000 m (6562 ft). Above 2000 m (6562 ft), see page 72.

104
Isolation and grounding diagram
(Test voltage: 500 V AC)

X20
1 VREF-
2 AGND
X21
1 VREF+
2 AGND
3 AI1+
4 AI1- Common mode
voltage between
5 AI2+
channels ±15 V
6 AI2-
7 AI3+
8 AI3-
9 AO1+
10 AO1-
11 AO2+
12 AO2-
X22
1 DI1
2 DI2
3 DI3
4 DI4
Jumper J1 settings:
9 DGND1
5 DI5 All digital inputs share a common

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

105
Installation checklist
Check the mechanical and electrical installation of the drive before start-up. Go
through the checklist below together with another person. Read the Safety
instructions on the first pages of this manual before you work on the unit.
MECHANICAL INSTALLATION
The ambient operating conditions are allowed. See Electrical installation, Technical data: Ratings or Ambient
conditions.
The unit is fixed properly to floor. See Mechanical installation.
The cooling air will flow freely.
ELECTRICAL INSTALLATION See Planning the electrical installation, Electrical installation.
The motor and the driven equipment are ready for start.
The EMC filter (option +E202) is disconnected if the drive is connected to an IT (ungrounded) system.
The drive is grounded properly:

1) adequately sized PE conductor
2) properly tightened PE conductor.
The supply (input power) voltage matches the nominal input voltage of the drive.
The supply (input power) connection to the input terminals are OK and the phase order is correct.
Appropriate supply (input power) fuses are installed.
The motor connections at the output terminals are OK.
The motor cable is routed away from other cables.
Settings of the auxiliary voltage transformer of the drive.
Settings of the internal transformer in the DSU.
There are no power factor compensation capacitors in the motor cable.
The external control connections of the drive are OK.
There are no tools, foreign objects or dust from drilling inside the drive.
Supply (input power) voltage cannot be applied to the output of the drive (with a bypass connection).
For drives with Category 1 Emergency stop function (option +Q952 or +Q964): The time relay has been set to a
suitable value (somewhat longer than the stop ramp of the inverter units).
All shrouds are in place.

106
Start-up procedure
This section instructs how to start-up the ACS800-07 drive. The instructions do not
cover all possible tasks of all possible variants of the drive as the compositon of the
make-to-order drives vary. Always refer to the delivery-specific circuit diagrams
when performing the drive start-up. The device designations in square brackets, for
example [Q10], refer to the designations used in the circuit diagrams typically.
WARNING! Only qualified electricians are allowed to carry out the work described in
this chapter. Read the chapter Safety instructions before you start the work. Ignoring
the safety instructions can cause injury or death.
Action Additional information

WARNING! Ensure that the disconnector of the supply transformer is
locked in the open position, ie, no voltage is, or cannot be connected to
drive inadvertently. Check also by measuring that there is no voltage
connected.
Check that the main disconnecting device of the supply unit is open:
- Drives with a main breaker [Q1] (option +F255): The breaker is in the
withdrawn position (racked out).
- Drives with a main switch-disconnector (option +F253): The switch is in
the open position.
- Other drives (no option +F253 or +F255): The main switch
disconnector is locked in the open position.
Basic checks with no voltage connected
If the unit is equipped with a main breaker [Q1], set the current trip limits Optional device (+F255). See the
of the breaker. The trip limits have been preset to generic values by the delivery specific circuit diagrams and
breaker manufacturer. The generic limits do not correspond the the manuals of the breaker.
protection requirements of the application. For the limit rules, see below.
General rule
Ensure that the selectivity condition is fulfilled, ie, the breaker trips at a
lower current than the protection device of the supplying network, and
that the limit is high enough not to cause unnecessary trips during the
intermediate DC circuit load peak at start.
Long-term current limit
As a rule of thumb, this should be set to the rated AC current of the
module.
Peak current limit
As a rule of thumb, this should be set to a value 3 - 4 times the rated AC
current of the module.
Check the settings of any adjustable relays and breakers/switches in the Composition varies. See delivery
auxiliary circuits. specific circuit diagrams.
Disconnect any unfinished or unchecked 230/115-VAC cables that lead
from the terminal blocks to the outside of the equipment.
Locate the PPCS branching unit(s) (APBU-xx). Enable memory backup As standard, memory backup is
battery by setting actuator 6 of switch S3 to ON. switched off to save the battery.
Check the voltage setting of the auxiliary voltage transformer of the See page 96.
drive [T10].
Check the voltage setting of the auxiliary voltage transformer in the DSU See page 97.
module.

107

Connecting voltage to input terminals and auxiliary circuit
WARNING! When voltage is connected to the input terminals, voltage
may also be connected to the auxiliary circuits of the drive unit(s).
Make sure that it is safe to apply voltage. Ensure that:
• nobody is working on the unit or circuits that are wired from outside into
the cabinets
• covers of motor terminal boxes are in place.
Close the circuit breaker which connects the 24 V DC supply voltage for
the boards [F7].
Close the circuit breaker which connects the supply voltage for the AC
fans and 24 V DC power supply [F11].
Close the circuit breaker which connects the supply voltage for the fan in Only with option +F253 or +F255.
the incoming cubicle [F101].
Close the circuit breaker which connects the control voltage for the main Only with option +F255.
breaker [F12].
Close the circuit breaker which connects the control voltage for the Only with options Q951, Q952, Q963
optional emergency stop circuit [F21]. and Q964.
Close the circuit breaker [F5] which connects the measuring board Only with option +F253 or +F255.
(BAMU) to the main circuit.
Check the circuit diagrams and close any other breakers and switches in
the auxiliary circuit. The composition vary depending on the options of
the drive.
Close the doors of the cabinets.
Close the main breaker of the supply transformer.
Close the auxiliary circuit switch [Q10].
Starting the supply unit
WARNING! If the drive is equipped with a brake unit, make sure there Optional unit +D150.
are inverters connected to the intermediate circuit before start. As a rule If there is not enough capacitive load
of thumb, the sum capacitance of the inverters connected must be at at start, the DC voltage will overshoot
least 30% of the sum capacitance of all inverters. the controller voltage limit, causing
immediate start of braking. An
unloaded supply unit keeps the DC
voltage high and the chopper
remains conductive.
Open the grounding switch (if present) and close the drive main Optional device (option +F259). See
disconnecting device. delivery specific circuit diagrams.
Note: The grounding switch and the main disconnecting device are
either mechanically coupled or electrically interlocked: The grounding
switch can be closed only when the main disconnecting device is open.
The disconnector can be closed only when the grounding switch is open.
Close the drive main disconnecting device: See delivery specific circuit
Units with a main breaker (option +F255): diagrams.
Unlock the withdrawn breaker and rack it in.
Units with a main switch-disconnector (option +F253):
Unlock the switch and turn it into the closed position.

108

Close the main contactors (option +F250] or the main breaker [Q1]
(option +F255), and start the DSU: Turn the three-position operating
switch [S11] on the cabinet door from 0 to the START position for 2 s.
Setting up the supply unit control program
Check the settings of the supply unit control program. See section Start-up in ACS800
diode supply control program
firmware manual
(3AUA0000068937[English]).
Setting up the drive application program
Select the application macro and adjust the parameter settings of the Appropriate Firmware Manual of the
drive application program to meet the application needs. drive application program delivered
with the drive.
On-load checks
Check the correct operation of the emergency stop circuits from each Optional device (options +Q951,
operating location. +Q952, +Q963, +Q964). See
If the drive is equipped with the category 1 emergency stop function delivery specific circuit diagrams and
(option +Q952 or +Q964), adjust the delay time of the emergency stop Safety options instructions for
relay and the deceleration time of the drive emergency stop function. ACS800 drives (3AUA0000026238
The factory default settings do not necessarily meet the application [English]).
needs.
Check that the Prevention of unexpected start-up function from each Optional function (+Q950). See
operating location. delivery specific circuit diagrams and
Safety options instructions for
ACS800 drives (3AUA0000026238
[English]).
Check the correct operation of the Safe torque off function from each Optional function (options +Q967,
operating location. +Q968). See delivery specific circuit
diagrams and Safety options
instructions for ACS800 drives
(3AUA0000026238 [English]).
Activate and check the operation of the power loss ride-through function. See ACS800 diode supply control
if automatic restart is required/allowed after a short power supply break. program firmware manual
(3AUA0000068937[English]).
If the earth fault monitoring is used, check its settings. Optional device (option +Q954). See
the documentation of the monitoring
device delivered with the drive or
from www.bender.org.
Check that the cooling fans rotate freely in the right direction, and the air Check visually that the fans rotate in
flows upwards. the direction indicated by an arrow
on the fan housing.
Check the direction of rotation of the motor.

109
Maintenance

This chapter contains preventive maintenance instructions.
Maintenance intervals
This table lists the routine maintenance intervals recommended by ABB.
Interval Maintenance action Instructions
Every year of storage Reforming the capacitor See document Capacitor reforming instructions
(Code: 3BFE 64059629 [English]) and
Capacitors.
Every 6 to 12 months Checking the heatsink temperature See Heatsinks.
(depending on the dustiness of and cleaning
the environment)
Every year [IP22 and IP42 units Checking the air filter; replacing it if See Replacing the PPCS branching unit
(+B053 and +B054)] necessary (APBU-xx) memory backup battery.
Every year [IP54 units (+B055 Replacing the air filter
and +B059)]
Every year Checking the fuses of CVAR; For the fuse type, see Fuses on the CVAR
replacing them if necessary board.
Every 3 years Checking the cooling fan; replacing See Cooling fans.
it if necessary
Every 3 years Checking power connections and See Checking the connections of the power
cleaning cables.
Every 3 years Changing the cooling fans of See Cooling fans.
supply, inverter and brake module
(in a 60-Hz supply network)
Every 6 years Replacing the memory backup Locate the APBU unit. See section Replacing
battery of the PPCS branching unit the PPCS branching unit (APBU-xx) memory
(APBU-xx) backup battery on page 113.
Checking the tightness of the See Tightening torques for power connections
Every 6 years
power connections on page 135.
Every 6 years Changing the cooling fans of See Cooling fans.
supply, inverter and brake module
(in a 50-Hz supply network)
Every 9 years (if drive subjected Changing the capacitor See Capacitors.
to high ambient temperature)
Every 9 years Replacing the CINT board in the Contact your local ABB Service representative.
DSU module
Every 12 years Changing the capacitor See Capacitors.
Consult your local ABB Service representative for more details on the maintenance.
On the Internet, go to http://www.abb.com/drives and select Drive Services –
Maintenance and Field Services.
Maintenance
110
Redundancy (Reduced run capability)

If one of the parallel-connected supply or inverter modules must be taken out of the
cabinet for service, it is possible to continue operation using the remaining modules
at reduced power.
Removing a DSU module and selecting the Reduced run feature

Note: The maximum number of removed DSU modules is limited to 50% of the
original number of parallel-connected modules.
WARNING! Read and follow the instructions in chapter Safety instructions. Ignoring
1. Switch off the power to the unit and open the main disconnecting device. Close
the grounding switch (option +F259) if there is one.
2. Let the intermediate circuit DC capacitors discharge for five minutes. Ensure by
measuring that the drive is not live before starting the work.
3. Extract the module to be serviced from the cabinet. Follow the directions given in
section Connection procedure on page 79.
4. Fasten the air baffle(s) provided with the unit to the top module guide (A) to
block airflow through the empty module bay (B). See the figures below.
A B
Maintenance
111
5. Close the cabinet doors.

6. Switch on the auxiliary control voltage of the drive.
7. Switch the panel from the inverter unit to the DSU. The supply and inverter units
are connected to the same panel through a panel link. The panel communicates
with either one at the time. The switching between the nodes online is instructed
in chapter Control panel in the Firmware manual of the drive application
program.
8. Make the necessary parameter adjustments in the drive firmware. Refer to the
appropriate Firmware manual of the drive application program.
9. Set the number of the existing supply modules and activate the Reduced run
function with parameter 16.10 INT CONFIG USER. For more information, refer
to ACS800 diode supply control program firmware manual
(3AUA0000068937[English]).
Maintenance
112
Removing an inverter module and selecting the Reduced run feature
3. Extract the module to be serviced from the cabinet. Follow the directions given
on page 89.
4. Fasten the air baffle provided with the unit to the top module guide to block
airflow through the empty module bay. The installation principle is described on
page 110.
6. Switch on the auxiliary control voltage of the drive.
7. Switch the panel from DSU communication to inverter communication. The
supply and inverter units are connected to the same panel through a panel link.
The panel communicates with either one at the time. The switching is instructed
in chapter Control panel in the Firmware manual of the drive application
program.
8. Make the necessary parameter adjustments in the drive firmware. Refer to the
appropriate Firmware manual of the drive application program. For example, if
the ACS800 standard control program is in use, decrease the number of parallel
inverter modules to the appropriate value by parameter 95.03 INT CONFIG.
Maintenance
113
Replacing the PPCS branching unit (APBU-xx) memory backup battery
3. Locate the branching units in the auxiliary control cubicle. Remove any shrouds.
4. Open the screws on the cover (3 pcs, indicated with arrows in the figure below).
5. Slide off the cover.
6. Remove the battery.
7. Insert the new CR 2032 battery and reattach the cover.
4 5 6
Maintenance
114
Checking and replacing the air filters
3. Open the cabinet doors.
4. Check the air filters and replace if necessary (see Technical data for the correct
filter types). The inlet (door) filters can be accessed by removing the fastener(s)
at the top of the grille, then lifting the grille and pulling it away from the door. The
outlet (roof) filter in IP54 (+B055) units has a similar mechanism.
5. Check the cleanliness of the cabinet. Clean the interior of the cabinet if
necessary using a soft brush and a vacuum cleaner.
Checking the connections of the power cables
3. Open the cabinet doors.
4. Extract one supply or inverter module from the cabinet as described in the
connection procedures in the chapter Electrical installation.
5. Check the tightness of the cable connections at the quick connector. Use the
tightening torque table in Technical data.
6. Clean all contact surfaces of the quick connector and apply a layer of suitable
joint compound (eg, Isoflex® Topas NB 52 from Klüber Lubrication) onto them.
7. Re-insert the supply/inverter module.
8. Repeat steps 4 to 7 for all remaining supply and inverter modules.
Maintenance
115
Cooling fans
Supply, inverter and brake module cooling fans

The actual lifespan of the fan depends on the running time of the fan, ambient
temperature and dust concentration. Each supply and inverter module has its own
cooling fan. Replacements are available from ABB. Do not use other than ABB
specified spare parts.
The application program keeps track of the running time of the cooling fan of the
inverter modules. See the Firmware manual of the drive application program for the
actual signal which indicates the running time.
Replacing the fan of the supply module
3. Open the supply module cubicle doors.
4. Loosen the locking screw (marked with letter A in the figure below).
5. Disconnect the fan wiring plug (B).
6. Pull out the fan (C).
7. Install a new fan in reverse order.
Maintenance
116
Replacing the fan of the inverter and brake module
3. Open the inverter module cubicle doors.
4. Disconnect the fan wiring plug (marked with letter A in the figure below).
5. Remove the locking screws (B).
6. Pull the fan out along its sliding rails (C).
7. Install a new fan in reverse order.
Maintenance
117
Replacing the fans in the auxiliary control cubicle
3. Open the door of the auxiliary control cubicle (or combined auxiliary control
cubicle and supply cubicle).
4. Detach the wiring from each fan (AC plug and grounding wire).
5. Undo the four fastening screws of the fan assembly and pull the assembly
outwards to gain access to the fan fastening screws.
6. Undo the fastening screws of the fans (there are four for each fan) from below.
Remove the fans.
7. Install new fans in reverse order. Before fastening the fans, make sure the
airflow arrow on both fans is pointed up.
4 4
5
6
Maintenance
118
Replacing the fan in the incoming cubicle with the main breaker (option +F255)
Certain IP2x/IP4x (+B053 and +B054) units with a main breaker are also fitted with
two fans at the air outlet on the roof. Replace the fans as follows:
3. Remove the grating (A) and the two fans by undoing the four screws (B).
4. If necessary, undo the four screws (C) to remove the airflow guide (D).
B
B C
D
C
Maintenance
119
Replacing the additional fans in the IP54 / UL type 12 drives (+B055 and +B059)
3. Remove the front and back gratings of the fan compartment by lifting them
upwards.
4. Remove the shrouds by undoing the fastening screws.
5. Undo the fastening screws of the side/top cover of the fan.
6. Lift the side/top cover of the fan off.
7. Disconnect the fan supply wire connector from the cabinet roof (on top and
inside the cabinet).
8. Undo the fastening screws of the fan cassette at each corner.
9. Lift the fan cassette off.
10. Undo the cable ties on the top of the fan cassette.
11. Disconnect the cables (detachable terminals).
12. Remove the fan capacitor by undoing the fastening screw of the clamp.
13. Undo the fastening screws of the fan.
14. Pull the fan out.
15. Install the new fan and fan capacitor in reverse order to the above. Ensure that
the fan is centered and rotates freely.
Maintenance
120
4 4 6
3
5
4
4
5
9
8
7
7
12
11
10
10
11
10 10
14
13 13
Maintenance
121
Heatsinks
The heatsink fins of the power modules pick up dust from the cooling air. The
module runs into overtemperature warnings and faults if the heatsinks are not clean.
In a “normal” environment (not especially dusty nor clean) the heatsinks should be
checked annually, in a dusty environment more often.
Cleaning the heatsink
3. Remove the cooling fan (see section Cooling fans).
4. Blow dry clean 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.
5. Refit the cooling fan.
Capacitors
The inverter modules employ several electrolytic capacitors. Their lifespan is at least
90 000 hours depending on the operating time of the drive, loading and ambient
temperature. The life of a capacitor can be prolonged by lowering the ambient
temperature.
It is not possible to predict a capacitor failure. A capacitor failure is usually followed
by damage to the unit and an input cable fuse failure, or a fault trip. Contact ABB if a
capacitor failure is suspected.
Reforming the electrolytic capacitors

Reform (re-age) spare part capacitors once a year according to Capacitor reforming
guide (code: 64059629 [English], available through your local ABB representative.
Capacitor replacement
Contact an ABB service representative.
Maintenance
122
Safety function checks in the maintenance routine

It is a good practice to check the operation of the optional safety functions at
appropriate intervals.
If the drive is equipped with optional safety functions +Q950, +Q951, +Q952, +Q954,
+Q963, +Q964 or Q968, include the safety function tests described in Safety options
instructions for ACS800 drives (3AUA0000026238 [English]) to the routine
maintenance program of the machinery that the drive runs.
If you replace a circuit board or wire set inside the drive module, re-test the safety
function.
If you detect any failure in safety functions, contact your local ABB representative.
Other maintenance actions
Replacement of a supply inverter or brake modules

To replace supply, inverter or three-phase brake modules, follow the instructions on
the module removal and refitting given in chapter Electrical installation. The brake
modules are identical with the inverter modules.
Maintenance
123
Fault tracing

This chapter instructs in interpreting the LED indications of the ACS800-07 (+V992)
drive.
Note: Information on warnings and faults reported by the application program (and
displayed on the control panel on the cabinet door) are contained within the
Firmware manuals delivered with the drive.
Supply module LED

There is the following LED on the cover of the CINT board.
V 2
R M IO
V 1
P O W E R
O N
3 A U A 0 0 0 0 0 3 1 1 8 9
R e v . B
The circuit board is powered when the green LED is on.
Fault tracing
124
Other LEDs of the drive
Location LED Indication
RMIO board (RDCU control unit) Red Drive in the fault state.
Green Power supply on the board is OK.
Control panel mounting platform Red Drive in the fault state.
(with the control panel removed)
Green Main + 24 V power supply for the control panel and the RMIO
board is OK.
AINT board (visible through the V204 (green) +5 V voltage of the board is OK.
transparent cover on the front of the
V309 (red) Prevention of unexpected start-up or Safe torque off is ON.
inverter modules)
V310 (green) IGBT control signal transmission to the gate driver control
boards is enabled.
Fault tracing
125
Technical data

This chapter contains the technical specifications of the drive, eg, ratings, frame
sizes and technical requirements, provisions for fulfilling the requirements for CE
and other markings.
Ratings
The ratings for the ACS800-07 (+V992) with 50 Hz and 60 Hz supplies are given
below. The symbols are described below the table.
Nominal No-over- Light- Heavy-duty Heat dis- Noise
Air flow
ACS800-07 (+V992) ratings load use overload use use sipation level
type Icont.max Imax Pcont.max I2N PN I2hd Phd
A A kW A kW A kW kW m3/h dBA
Three-phase supply voltage 380 V, 400 V or 415 V
ACS800-07-0610-3 879 1315 500 844 500 657 400 13.0 3120 73
ACS800-07-0770-3 1111 1521 630 1067 630 831 450 17.2 3840 74
ACS800-07-0870-3 1255 1877 710 1205 710 939 500 18.5 3840 74
ACS800-07-1030-3 1452 1988 800 1394 800 1086 630 23.9 3840 74
ACS800-07-1230-3 1770 2648 1000 1699 1000 1324 710 27.5 5040 75
ACS800-07-1540-3 2156 2951 1200 2070 1200 1613 900 35.4 5760 76
ACS800-07-1850-3 2663 3894 1450 2556 1450 1992 1120 42.7 6960 76
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V
ACS800-07-0760-5 883 1321 630 848 630 660 500 14.0 3120 73
ACS800-07-0910-5 1050 1524 710 1008 710 785 560 17.2 3840 74
ACS800-07-1090-5 1258 1882 900 1208 900 941 630 19.9 3840 74
ACS800-07-1210-5 1372 1991 1000 1317 1000 1026 710 23.8 3840 74
ACS800-07-1540-5 1775 2655 1250 1704 1200 1328 900 29.4 5040 75
ACS800-07-1820-5 2037 2956 1450 1956 1400 1524 1120 35.0 5760 76
ACS800-07-2310-5 2670 3901 1900 2563 1850 1997 1400 45.4 6960 76
Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V, or 690 V
ACS800-07-0750-7 628 939 630 603 630 470 500 13.9 3120 73
ACS800-07-0870-7 729 1091 710 700 710 545 560 17.1 3120 73
ACS800-07-1060-7 885 1324 800 850 800 662 630 18.4 3120 73
ACS800-07-1160-7 953 1426 900 915 900 713 710 20.8 3840 74
ACS800-07-1500-7 1258 1882 1200 1208 1200 941 900 27.0 5040 75
ACS800-07-1740-7 1414 2115 1400 1357 1400 1058 1000 32.5 5040 75
ACS800-07-2120-7 1774 2654 1700 1703 1700 1327 1250 40.1 6240 76
ACS800-07-2320-7 1866 2792 1900 1791 1800 1396 1400 43.3 6960 76
ACS800-07-2900-7 2321 3472 2300 2228 2200 1736 1600 51.5 8160 77
ACS800-07-3190-7 2665 3987 2600 2558 2500 1993 1900 58.0 9360 78
ACS800-07-3490-7 2770 4144 2800 2659 2700 2072 2100 63.6 10080 78
PDM-184674-0.36
Technical data
126
Symbols
Nominal ratings
Icont.max Continuous RMS output current. No overloadability at 40 °C.
Imax Maximum output current. Allowable for 10 seconds at start, otherwise as long as allowed
by drive temperature.
Typical ratings for no-overload use
Pcont.max Typical motor power. The power ratings apply to most IEC 34 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 34 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 34 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
(3281 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
by 1% for every additional 1 °C (1.8 °F). The output current is calculated by multiplying the current
given in the rating table by the derating factor.
Example If the ambient temperature is 50 °C (+122 °F), the derating factor is 100% - 1 % · 10 °C =
90% or 0.90. The output current is then 0.90 × I or 0.90 × I . °C
2N cont.max
Altitude derating
At altitudes from 1000 to 4000 m (3281 to 13123 ft) above sea level, the derating is 1% for every 100 m
(328 ft). For a more accurate derating, use the DriveSize PC tool. 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
127
ACS800-07 (+V992) frame sizes and power module types

Frame size Supply module(s) used Inverter modules used
ACS800-07 (+V992)
(supply+inverter
type Qty Type Qty Type
modules)
Three-phase supply voltage 380 V, 400 V or 415 V
ACS800-07-0610-3 1×D4 + 2×R8i 1 ACS800-704-0910-7 2 ACS800-104-0390-3
ACS800-07-0770-3 2×D4 + 2×R8i 2 ACS800-704-0640-7 2 ACS800-104-0390-3
ACS800-07-0870-3 2×D4 + 2×R8i 2 ACS800-704-0640-7 2 ACS800-104-0510-3
ACS800-07-1030-3 2×D4 + 2×R8i 2 ACS800-704-0910-7 2 ACS800-104-0510-3
ACS800-07-1230-3 2×D4 + 3×R8i 2 ACS800-704-0910-7 3 ACS800-104-0510-3
ACS800-07-1540-3 3×D4 + 3×R8i 3 ACS800-704-0910-7 3 ACS800-104-0510-3
ACS800-07-1850-3 3×D4 + 4×R8i 3 ACS800-704-0910-7 4 ACS800-104-0510-3
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V
ACS800-07-0760-5 1×D4 + 2×R8i 1 ACS800-704-0910-7 2 ACS800-104-0460-5
ACS800-07-0910-5 2×D4 + 2×R8i 2 ACS800-704-0640-7 2 ACS800-104-0460-5
ACS800-07-1090-5 2×D4 + 2×R8i 2 ACS800-704-0640-7 2 ACS800-104-0610-5
ACS800-07-1210-5 2×D4 + 2×R8i 2 ACS800-704-0910-7 2 ACS800-104-0610-5
ACS800-07-1540-5 2×D4 + 3×R8i 2 ACS800-704-0910-7 3 ACS800-104-0610-5
ACS800-07-1820-5 3×D4 + 3×R8i 3 ACS800-704-0910-7 3 ACS800-104-0610-5
ACS800-07-2310-5 3×D4 + 4×R8i 3 ACS800-704-0910-7 4 ACS800-104-0610-5
Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V, or 690 V
ACS800-07-0750-7 1×D4 + 2×R8i 1 ACS800-704-0640-7 2 ACS800-104-0440-7
ACS800-07-0870-7 1×D4 + 2×R8i 1 ACS800-704-0910-7 2 ACS800-104-0440-7
ACS800-07-1060-7 1×D4 + 2×R8i 1 ACS800-704-0910-7 2 ACS800-104-0580-7
ACS800-07-1160-7 2×D4 + 2×R8i 2 ACS800-704-0640-7 2 ACS800-104-0580-7
ACS800-07-1500-7 2×D4 + 3×R8i 2 ACS800-704-0640-7 3 ACS800-104-0580-7
ACS800-07-1740-7 2×D4 + 3×R8i 2 ACS800-704-0910-7 3 ACS800-104-0580-7
ACS800-07-2120-7 2×D4 + 4×R8i 2 ACS800-704-0910-7 4 ACS800-104-0580-7
ACS800-07-2320-7 3×D4 + 4×R8i 3 ACS800-704-0910-7 4 ACS800-104-0580-7
ACS800-07-2900-7 3×D4 + 5×R8i 3 ACS800-704-0910-7 5 ACS800-104-0580-7
ACS800-07-3190-7 3×D4 + 6×R8i 3 ACS800-704-0910-7 6 ACS800-104-0580-7
ACS800-07-3490-7 4×D4 + 6×R8i 4 ACS800-704-0910-7 6 ACS800-104-0580-7
PDM-184674-0.32
Technical data
128
AC fuses
ACS800- Input Rated I2t I2t
Type Voltage I2t
07+V992… current Qty. current Clearing at Clearing at
(IEC/UL/CSA) (V) Pre-arc
type (A) (A RMS) 660V 210000 [A2s]
UN = 400 V (Range 380-415 V)
-0610-3 790 6
-0770-3 999 12
-0870-3 1128 12 170M6410
-1030-3 1305 12 630 690 31000 210000 210000
Bussmann
-1230-3 1591 12
-1540-3 1938 18
-1850-3 2394 18
UN = 500 V (Range 380-500 V)
-0760-5 793 6
-0910-5 944 12
-1090-5 1131 12
170M6410
-1210-5 1233 12 630 690 31000 210000 210000
Bussmann
-1540-5 1596 12
-1820-5 1831 18
-2310-5 2400 18
UN = 690 V (Range 525-690 V)
-0750-7 565 6
-0870-7 655 6
-1060-7 795 6
-1160-7 856 12
-1500-7 1131 12
170M6410
-1740-7 1271 12 630 690 31000 210000 210000
-2120-7 1595 12 Bussmann
-2320-7 1678 18
-2900-7 2086 18
-3190-7 2396 18
-3490-7 2490 24
*If the drive is not equipped with internal AC fuses (option code +F260), install specified fuses externally at the AC
supply. See the diagram on page 77 for the cabling arrangement at each supply module.
Technical data
129
DC fuses at inverter module input

Input Rated
ACS800- current Type
Qty. Type (IEC) current Voltage (V)
07… type (UL/CSA)
(A) (A RMS)
UN = 400 V (Range 380-415 V)
-0610-3 790 4 170M8547 170M6216
1250 690
-0770-3 999 4 Bussmann Bussmann
-0870-3 1128 4
-1030-3 1305 4
170M8550 170M6219
-1230-3 1591 6 1600 690
Bussmann Bussmann
-1540-3 1938 6
-1850-3 2394 8
UN = 500 V (Range 380-500 V)
-0760-5 793 4 170M8547 170M6216
1250 690
-1090-5 1131 4
-1210-5 1233 4
170M8550 170M6219
-1540-5 1596 6 1600 690
Bussmann Bussmann
-1820-5 1831 6
-2310-5 2400 8
UN = 690 V (Range 525-690 V)
-0750-7 565 4 170M8647 170M8637
800 1000
-1060-7 795 4
-1160-7 856 4
-1500-7 1131 6
-1740-7 1271 6
170M8650 170M8639
-2120-7 1595 8 1000 1000
Bussmann Bussmann
-2320-7 1678 8
-2900-7 2086 10
-3190-7 2396 12
-3490-7 2490 12
Fuses for main circuit voltage measurement for the BAMU board
The fuse type is Ferraz A070GRC01T13, 1 A 700 V AC 160 kA.
Fuses on the CVAR board

The fuse type is Ferraz A070GRB10T13/G330010 10 A 700 V AC.
DC fuses for the DSU module

Each D4 type DSU module uses four fuses. The fuses are located inside the DSU
module. The DC fuse is Bussmann 170M4908 (with fuse indicators that are both
IEC- and UL-recognized).
Technical data
130
Input power connection

Voltage (U1) 380/400/415 VAC 3-phase ± 10% for 400 VAC units
380/400/415/440/460/480/500 VAC 3-phase ± 10% for 500 VAC units
525/550/575/600/660/690 VAC 3-phase ± 10% for 690 VAC units
Short-circuit withstand Drives without grounding switch (option +F259): Maximum allowable prospective short-
strength (IEC 60439-1) circuit current is 65 kA. The peak withstand current is 143 kA.
Drives with grounding switch (option +F259): Maximum allowable prospective short-circuit
current is 50 kA. The peak withstand current is 105 kA.
Short-circuit current The drive is suitable for use on a circuit capable of delivering not more than 100,000 rms
protection (UL 508A) symmetrical amperes at 600 V maximum when protected by fuses given in the fuse
tables.
Short-circuit current The drive is suitable for use on a circuit capable of delivering not more than 65 kA rms
protection (CSA C22.2 No. symmetrical amperes at 600 V maximum when protected by fuses given in the fuse
14-05) tables.
Frequency 48 to 63 Hz, maximum rate of change 17%/s
Imbalance Max. ± 3% of nominal phase to phase input voltage
Fundamental power factor 0.98 (at nominal load)

(cos phi1)
Transformer for 12-pulse Connection Dy 11 d0 or Dyn 11 d0

supply
Phase shift between 30° electrical
secondaries
Voltage difference between < 0.5%
secondaries
Short-circuit impedance of > 5%
secondaries
Short-circuit impedance < 10% of short-circuit
difference between impedance
secondaries
Other No grounding of the secondaries allowed.
Static screen recommended
Input power cable lead- Units without main switch-disconnector or main breaker (no option +F253 or +F255):
throughs 4 × Ø60 mm (2.36”) at each supply module
Units with a main switch-disconnector (option +F253):
9 × Ø60 mm (2.36”) (frame 1×D4 + 2×R8i)
12 × Ø60 mm (2.36”) (frame 2×D4 + n×R8i)
18 × Ø60 mm (2.36”) (frame 3×D4 + n×R8i and 4×D4 + n×R8i)
Units with a main breaker (option +F255):
18 × Ø60 mm (2.36”)
Technical data
131
Input terminals at each

supply module (units without Conductor size Max. no. and size of cable Lug hole Bolt Tightening
main switch-disconnector or lugs per phase torque
main breaker; no option +F253 IEC Cabling
or +F255) < 150 mm2 2 × 150 mm2 1 × 11 M10 40 Nm
185 … 240 mm2 OL 2 × 185-240 mm2 (with – – 15 Nm
dual-cable screw lug included
with delivery)
US Cabling
300 … 350 MCM 2 × 350 MCM 2 × 1¾” 7/16” 30 lbf.ft
Input terminals (units with

main switch-disconnector or Busbar dimensions No. of Bolt size Tightening
main breaker; option +F253 or busbars 2) torque
+F255)
13 [0.51] 40 [1.57]
M12 or 70 Nm
See below
½” (50 lb.ft)
50 [1.97]
Number of input busbars (6-pulse units)

No. of supply modules No. of busbars per connection point
(n×D4) 1L1 1L2 1L3
1 1 1 1
2 2 2 2
3 3 3 3
4 3 3 3
Number of input busbars (12-pulse units)

No. of supply modules No. of busbars per connection point
(n×D4) 1L1 1L2 1L3 2L1 2L2 2L3
1 1 1 1 1 1 1
2 2 2 2 2 2 2
3 3 3 3 3 3 3
4 3 3 3 3 3 3
Technical data
132
Motor connection
Voltage (U2) 0 to U1, 3-phase symmetrical, Umax at the field weakening point
Frequency DTC mode: 0 to 3.2 × fFWP. Maximum frequency 300 Hz.
UNmains
fFWP = · fNmotor
UNmotor
where fFWP = frequency at field weakening point; UNmains = mains (input power) voltage;
UNmotor = rated motor voltage; fNmotor = rated motor frequency
Frequency resolution 0.01 Hz
Current See section Ratings.
Power limit 2 × Phd. After approximately 2 minutes at 2 × Phd, the limit is set at Pcont.max.
Field weakening point 8 to 300 Hz
Switching frequency 2 kHz (average)
Motor cable lead-throughs 3 × Ø60 mm at each inverter module (units without common motor terminal cubicle, no
option +H359)
Units with common motor terminal cubicle (option +H359): See the chapter Dimensions.
Technical data
133
Output terminals at each R8i

Bottom exit Top exit
inverter module (units
without common motor Side view Side view
terminal cubicle, no option Bolt size: M12 or ½” Bolt size: M12 or ½”
+H359) Tightening torque: 70 Nm (52 lbf.ft) Tightening torque: 70 Nm (52 lbf.ft)
Cabling
direction
Cabling direction
68265631-A0 cabinet_400_generic.asm
Output terminals (units with 8 × Ø13 mm per phase. See the chapter Dimensions.
common motor terminal
cubicle, option +H359)
Maximum recommended 100 m (328 ft). Motor cables up to 500 m (1640 ft) long are allowed but EMC filtering
motor cable length within the specified limits will not be realised.
Efficiency
Approximately 98% at nominal power level
Technical data
134
Cooling
Method Internal fans, flow direction from bottom to top
Filter material Inlet (door) Outlet (roof)

IP22/IP42 units (+B053 and Luftfilter airTex G150 –
+B054)
IP54 units (+B055 and Luftfilter airComp 300-50 Luftfilter airTex G150
+B059)
Free space around the unit See chapter Mechanical installation.
Cooling air flow See Ratings.
Degrees of protection
IP21; IP22; IP42; IP54, IP54R (with air outlet duct)
Ambient conditions
Environmental limits for the drive are given below. The drive must be used in a heated,
indoor controlled environment.
Operation Storage Transportation
installed for stationary use in the protective package in the protective package
Installation site altitude Supply voltage < 600 V AC: - -
max. 4000 m, except drives
with options +Q963, +Q964
and +Q968: max. 2000 m
Supply voltage > 600 V AC

(max. 690 V AC):
- IT (ungrounded) and
corner-grounded networks:
max. 2000 m
- TN (grounded) networks:
max. 4000, except drives
with options +Q963, +Q964
and +Q968: max. 2000 m
Note: Above 1000 m

(328 ft), see also section
Derating.
Air temperature -15 to +50 °C (5 to 122 °F), -40 to +70 °C (-40 to +158°F) -40 to +70 °C (-40 to +158°F)
no frost allowed. See section
Derating.
Relative humidity 5 to 95% Max. 95% Max. 95%
No condensation allowed. Maximum allowed relative humidity is 60% in the presence of
corrosive gases.
Technical data
135
Contamination levels No conductive dust allowed.

(IEC 60721-3-3, IEC 60721-3- Boards without coating: Boards without coating: Boards without coating:
2, IEC 60721-3-1) Chemical gases: Class 3C1 Chemical gases: Class 1C2 Chemical gases: Class 2C2
Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2
Boards with coating: Boards with coating: Boards with coating:
Chemical gases: Class 3C2 Chemical gases: Class 1C2 Chemical gases: Class 2C2
Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2
Atmospheric pressure 70 to 106 kPa 70 to 106 kPa 60 to 106 kPa
0.7 to 1.05 atmospheres 0.7 to 1.05 atmospheres 0.6 to 1.05 atmospheres
Vibration (IEC 60068-2) Max. 1 mm (0.04 in.) Max. 1 mm (0.04 in.) Max. 3.5 mm (0.14 in.)
(5 to 13.2 Hz), (5 to 13.2 Hz), (2 to 9 Hz),
max. 7 m/s2 (23 ft/s2) max. 7 m/s2 (23 ft/s2) max. 15 m/s2 (49 ft/s2)
(13.2 to 100 Hz) sinusoidal (13.2 to 100 Hz) sinusoidal (9 to 200 Hz) sinusoidal
Shock (IEC 60068-2-27) Not allowed Max. 100 m/s2 (330 ft./s2), Max. 100 m/s2 (330 ft./s2),
11 ms 11 ms
Free fall Not allowed 100 mm (4 in.) for weight 100 mm (4 in.) for weight
over 100 kg (220 lb) over 100 kg (220 lb)
Materials
Cabinet Hot-dip zinc-coated (thickness approx. 20 µm) steel sheet (thickness 1.5 mm) with
polyester thermosetting powder coating (thickness approx. 80 µm) on visible surfaces
except back panel. Colour: RAL 7035 (light beige, semigloss).
Busbars Tin- or silver-plated copper
Fire safety of materials Insulating materials and non-metallic items: Mostly self-extinctive
(IEC 60332-1)
Packaging Frame: Wood or plywood. Plastic wrapping: PE-LD. Bands: PP or steel.
Disposal The drive contains raw materials that should be recycled to preserve energy and natural
resources. The package materials are environmentally compatible and recyclable. All
metal parts can be recycled. The plastic parts can either be recycled or burned under
controlled circumstances, according to local regulations. Most recyclable parts are marked
with recycling marks.
If recycling is not feasible, all parts excluding electrolytic capacitors and printed circuit
boards can be landfilled. The DC capacitors (C1-1 to C1-x) contain electrolyte and the
printed circuit boards contain lead, both of which 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.
Tightening torques for power connections

Screw size Torque
M5 3.5 Nm (2.6 lbf.ft)
M6 9 Nm (6.6 lbf.ft)
M8 20 Nm (14.8 lbf.ft)
M10 40 Nm (29.5 lbf.ft)
M12 70 Nm (52 lbf.ft)
M16 180 Nm (133 lbf.ft)
Technical data
136
Applicable standards
The drive complies with the following standards. The compliance with the European Low
Voltage Directive is verified according to standards EN 50178, EN 61800-5-1 and
EN 60204-1.
• EN 50178 (1997) Electronic equipment for use in power installations.
• EN 61800-5-1: 2003 and
2007
• EN 60204-1 (2006) Safety of machinery. Electrical equipment of machines. Part 1: General requirements.
Provisions for compliance: The final assembler of the machine is responsible for installing
- an emergency-stop device
- a supply disconnecting device.
• EN 60529: 2001 (IEC 529) Degrees of protection provided by enclosures (IP code).
• IEC 60664-1 (2007) Insulation coordination for equipment within low-voltage systems. Part 1: Principles,
requirements and tests.
• EN 61800-3 (2004) EMC product standard including specific test methods
• UL 508C UL Standard for Safety, Power Conversion Equipment, third edition
• UL 508A UL Standard for Safety, Industrial Control Panels, first edition
• CSA C22.2 No. 14-05 Industrial control equipment
Technical data
137
CE marking
A CE mark is attached to the drive to verify that the unit follows the provisions of the European Low
Voltage and EMC Directives (Directive 2006/95/EC and Directive 2004/108/EC).
Definitions
EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to
operate without problems within an electromagnetic environment. Likewise, the equipment must not
disturb or interfere with any other product or system within its locality.
First environment includes establishments connected to a low-voltage network which supplies buildings
used for domestic purposes.
Second environment includes establishments connected to a network not supplying domestic
premises.
PDS of category C1: PDS of rated voltage less than 1000 V, intended for use in the first environment.
PDS of category C2: PDS of rated voltage less than 1000 V, which is neither a plug in device nor a
movable device and, when used in the first environment, is intended to be installed and commissioned
only by a professional.
PDS of category C3: PDS of rated voltage less than 1000 V, intended for use in the second
environment and not intended for use in the first environment.
PDS of category C4: PDS of rated voltage equal to or above 1000 V, or rated current equal to or above
400 A, or intended for use in complex systems in the second environment.
Compliance with the EMC Directive

The EMC Directive defines the requirements for immunity and emissions of electrical equipment used
within the European Union. The EMC product standard (EN 61800-3) covers requirements stated for
drives.
Compliance with the EN 61800-3

First environment (PDS of category C2)
The requirements of the EMC Directive can be met as follows for restricted distribution:
1. The drive is equipped with EMC filter +E202.
2. The motor and control cables are selected as specified in the Hardware Manual.
3. The drive is installed according to the instructions given in the Hardware Manual.
4. Maximum cable length is 100 metres (328 ft).
WARNING! The drive may cause radio interference if used in a residential or domestic environment.
The user is required to take measures to prevent interference, in addition to the requirements for CE
compliance listed above, if necessary.
Note: It is not allowed to install a drive equipped with EMC filter +E202 on IT (unearthed) systems. The
supply network becomes connected to earth potential through the EMC filter capacitors which may
cause danger or damage the unit.
Technical data
138
Second environment (PDS of category C3)

The requirements of the EMC Directive can be met as follows:
1. The drive is equipped with EMC filter +E210. The filter is suitable for TN (earthed) and IT
(unearthed) networks.
2. The motor and control cables are selected as specified in the drive manuals.
3. The drive is installed according to the instructions given in the drive manuals.
4. Maximum cable length is 100 metres (328 ft).
Second environment (PDS of category C4)
If the above listed provisions cannot be met, the requirements of the EMC Directive can be met as
follows for restricted distribution:
1. It is ensured that no excessive emission is propagated to neighbouring low-voltage networks. In
some cases, the natural suppression in transformers and cables is sufficient. If in doubt, the supply
transformer with static screening between the primary and secondary windings can be used.
Medium voltage network

Supply transformer
Neighbouring network
Static screen
Point of measurement
Low voltage Low voltage

Equipment
Drive
(victim)
Equipment Equipment
2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available
from the local ABB representative.
3. The motor and control cables are selected as specified in the drive manuals.
Machinery Directive
The drive complies with the European Union Machinery Directive 2006/42/EC requirements for a partly
completed machinery. For more information, see the Declaration of Incorporation by ABB Drives at the
end of this manual.
Technical data
139
“C-tick” marking
A “C-tick” mark is attached to each drive in order to verify compliance with the relevant standard
(IEC 61800-3 (1996) – Adjustable speed electrical power drive systems – Part 3: EMC product
standard including specific test methods), mandated by the Trans-Tasman Electromagnetic
Compatibility Scheme.
Definitions
EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to
operate without problems within an electromagnetic environment. Likewise, the equipment must not
disturb or interfere with any other product or system within its locality.
The Trans-Tasman Electromagnetic Compatibility Scheme (EMCS) was introduced by the Australian
Communication Authority (ACA) and the Radio Spectrum Management Group (RSM) of the New
Zealand Ministry of Economic Development (NZMED) in November 2001. The aim of the scheme is to
protect the radiofrequency spectrum by introducing technical limits for emission from
electrical/electronic products.
First environment includes establishments connected to a low-voltage network which supplies buildings
used for domestic purposes.
Second environment includes establishments connected to a network not supplying domestic
premises.
Restricted distribution: mode of sales distribution in which the manufacturer restricts the supply of
equipment to suppliers, customers or users who separately or jointly have technical competence in the
EMC requirements of the application of drives.
Unrestricted distribution: mode of sales distribution in which the supply of equipment is not dependent
on the EMC competence of the customer or user for the application of drives.
Compliance with IEC 61800-3

First environment (restricted distribution)
The drive complies with the limits of IEC 61800-3 with the following provisions:
1. The drive is equipped with EMC filter +E202.
3. The motor and control cables used are selected as specified in the drive manuals.
4. Maximum cable length is 100 metres.
Note: The drive must not be equipped with the EMC filter +E202 when installed to IT (unearthed)
systems. The mains becomes connected to earth potential through the EMC filter capacitors. In IT
systems this may cause danger or damage the unit.
Technical data
140
Second environment
The drive complies with the limits of IEC 61800-3 with the following provisions:
1. It is ensured that no excessive emission is propagated to neighbouring low-voltage networks. In
some cases, the natural suppression in transformers and cables is sufficient. If in doubt, the supply
transformer with static screening between the primary and secondary windings is strongly
recommended.
Medium voltage network

Supply transformer
Neighbouring network
Static screen
Point of measurement
Low voltage Low voltage

Equipment
Drive
(victim)
Equipment Equipment
3. The motor and control cables used are selected as specified in the drive manuals.
Technical data
141
Technical data
142
Technical data
143
Dimensions
Cabinet line-ups
The drive consists of cubicles built into a cabinet line-up. The tables below show the
composition of cabinet line-ups for each frame size and the standard combinations
of options. The dimensions are in millimetres.
Notes:
• The side panels increase the total line-up width by 30 millimetres (1.2”).
• The standard depth of the cabinet line-up is 650 mm (excluding door equipment
such as switches and air inlet gratings). This is increased by 130 millimetres
(5.1”) with top entry/exit models as well as units with cooling air intake through the
bottom of the cabinet.
• The measurements given apply to 6-pulse-input, non-UL/CSA units. For
dimensions of 12-pulse-input or UL/CSA units, contact your local ABB
representative.
The tables are followed by example dimensional drawings.
Dimensions
144
1×D4 + 2×R8i
*Brake chopper 1
*Brake chopper 2
*Brake chopper 3
Incoming cubicle
*Brake resistor 1
*Brake resistor 2
*Brake resistor 3
cubicle & supply
Auxiliary control
Inverter module
terminal cubicle
Common motor
module cubicle
Joining cubicle
EMC/RFI filter
Shipping split
Line-up width
(with +F253)
(kg approx.)
Net weight
cubicle
cubicle
widths
700 600 1300 1300 890
700 300 400 600 2000 2000 1490
700 400 600 1700 1700 1190
700 600 300 1600 1600 1060
700 300 400 600 300 2300 2300 1660
700 400 600 300 2000 2000 1360
700 600 400 400 2100 2100 1250
700 300 400 600 400 400 2800 2800 1850
700 400 600 400 400 2500 2500 1550
700 600 300 400 400 2400 2400 1420
700 300 400 600 300 400 400 3100 3100 2020
700 400 600 300 400 400 2800 2800 1720
700 600 200 400 800 400 800 1500 + 2400 3900 980 + 800
700 300 400 600 200 400 800 400 800 2200 + 2400 4600 1580 + 800
700 400 600 200 400 800 400 800 1900 + 2400 4300 1280 + 800
700 600 300 400 800 400 800 1600 + 2400 4000 1060 + 800
700 300 400 600 300 400 800 400 800 2300 + 2400 4700 1660 + 800
700 400 600 300 400 800 400 800 2000 + 2400 4400 1360 + 800
700 600 400 400 400 2500 2500 1430
700 300 400 600 400 400 400 3200 3200 2030
700 400 600 400 400 400 2900 2900 1730
700 600 300 400 400 400 2800 2800 1600
700 300 400 600 300 400 400 400 3500 3500 2200
700 400 600 300 400 400 400 3200 3200 1900
700 600 200 400 800 400 800 400 800 1500 + 3600 5100 980 + 1200
700 300 400 600 200 400 800 400 800 400 800 2200 + 3600 5800 1580 + 1200
700 400 600 200 400 800 400 800 400 800 1900 + 3600 5500 1280 + 1200
700 600 300 400 800 400 800 400 800 1600 + 3600 5200 1060 + 1200
700 300 400 600 300 400 800 400 800 400 800 2300 + 3600 5900 1660 + 1200
700 400 600 300 400 800 400 800 400 800 2000 + 3600 5600 1360 + 1200
*The number of brake choppers depends on drive type. See chapter Resistor braking.
Dimensions
145
2×D4 + 2×R8i
*Brake chopper 1
*Brake chopper 2
*Brake chopper 3
Incoming cubicle
Incoming cubicle
*Brake resistor 1
*Brake resistor 2
*Brake resistor 3
Auxiliary control
Inverter module
terminal cubicle
Common motor
Supply module
Joining cubicle
Shipping split
Line-up width
(with +F253)
(with +F255)
(kg approx.)
Net weight
cubicle
cubicle
cubicle
widths
400 600 600 1600 1600 1200
400 500 600 600 2100 2100 1580
400 600 600 600 2200 2200 1900
400 600 600 300 1900 1900 1370
400 500 600 600 300 2400 2400 1750
400 600 600 600 300 2500 2500 2070
400 600 600 400 400 2400 2400 1560
400 500 600 600 400 400 2900 2900 1940
400 600 600 600 400 400 3000 3000 2260
400 600 600 300 400 400 2700 2700 1730
400 500 600 600 300 400 400 3200 3200 2110
400 600 600 600 300 400 400 3300 3300 2430
400 600 600 200 400 800 400 800 1800 + 2400 4200 1290 + 800
400 500 600 600 200 400 800 400 800 2300 + 2400 4700 1670 + 800
400 600 600 600 200 400 800 400 800 2400 + 2400 4800 1990 + 800
400 600 600 300 400 800 400 800 1900 + 2400 4300 1370 + 800
400 500 600 600 300 400 800 400 800 2400 + 2400 4800 1750 + 800
400 600 600 600 300 400 800 400 800 2500 + 2400 4900 2070 + 800
400 600 600 400 400 400 2800 2800 1740
400 500 600 600 400 400 400 3100 3100 2120
400 600 600 600 400 400 400 3400 3400 2440
400 600 600 300 400 400 400 3100 3100 1910
400 500 600 600 300 400 400 400 3600 3600 2290
400 600 600 600 300 400 400 400 3700 3700 2610
400 600 600 200 400 800 400 800 400 800 1800 + 3600 5400 1290 + 1200
400 500 600 600 200 400 800 400 800 400 800 2300 + 3600 5900 1670 + 1200
400 600 600 600 200 400 800 400 800 400 800 2400 + 3600 6000 1990 + 1200
400 600 600 300 400 800 400 800 400 800 1900 + 3600 5500 1370 + 1200
400 500 600 600 300 400 800 400 800 400 800 2400 + 3600 6000 1750 + 1200
400 600 600 600 300 400 800 400 800 400 800 2500 + 3600 6100 2070 + 1200
*The number of brake choppers depends on drive type. See chapter Resistor braking.
Dimensions
146
2×D4 + 3×R8i
Common
Auxiliary Incoming Incoming Supply Inverter
motor Shipping Line-up Net weight
control cubicle cubicle module module
terminal split widths width (kg approx.)
cubicle (with +F253) (with +F255) cubicle cubicle
cubicle
400 600 800 1800 1800 1350
400 500 600 800 2300 2300 1730
400 600 600 800 2400 2400 2050
400 600 800 400 2200 2200 1540
400 500 600 800 400 2700 2700 1920
400 600 600 800 400 2800 2800 2240
2×D4 + 4×R8i
Common
Auxiliary Incoming Incoming Supply Inverter Inverter
control cubicle cubicle module module module
cubicle (with +F253) (with +F255) cubicle cubicle 1 cubicle 2
cubicle
400 600 600 600 2200 2200 1680
400 500 600 600 600 2700 2700 2060
400 600 600 600 600 2800 2800 2380
400 600 600 400 600 2600 2600 1870
400 500 600 600 400 600 3100 3100 2250
400 600 600 600 400 600 3200 3200 2570
3×D4 + 3×R8i
Common
Auxiliary Incoming Incoming Supply Inverter
control cubicle cubicle module module
cubicle (with +F253) (with +F255) cubicle cubicle
cubicle
400 800 800 2000 2000 1540
400 600 800 800 2600 2600 1940
400 600 800 800 2600 2600 2240
400 800 800 400 2400 2400 1730
400 600 800 800 400 3000 3000 2130
400 600 800 800 400 3000 3000 2430
3×D4 + 4×R8i
Common
cubicle
400 800 600 600 2400 2400 1870
400 600 800 600 600 3000 3000 2270
400 600 800 600 600 3000 3000 2570
400 800 600 400 600 2800 2800 2060
400 600 800 600 400 600 3400 3400 2460
400 600 800 600 400 600 3400 3400 2760
Dimensions
147
3×D4 + 5×R8i
Common
cubicle
400 800 800 600 2600 2600 2020
400 600 800 800 600 3200 3200 2420
400 600 800 800 600 3200 3200 2720
400 800 800 400 600 3000 3000 2210
400 600 800 800 400 600 3600 3600 2610
400 600 800 800 400 600 3600 3600 2910
3×D4 + 6×R8i
Common
cubicle
400 800 800 800 2800 2800 2170
400 600 800 800 800 3400 3400 2570
400 600 800 800 800 3400 3400 2870
400 800 800 600 800 3400 3400 2390
400 600 800 800 600 800 4000 4000 2790
400 600 800 800 600 800 4000 4000 3090
4×D4 + 6×R8i
Common
cubicle
400 600 + 600 800 800 3200 3200 2520
400 600 600 + 600 800 800 3800 3800 2920
400 600 600 + 600 800 800 3800 3800 3220
400 600 + 600 800 600 800 3800 3800 2740
400 600 600 + 600 800 600 800 4400 4400 3840
400 600 600 + 600 800 600 800 4400 4400 4140
Dimensions
148
Frame size 1×D4 + 2×R8i
Dimensions
149
Frame size 1×D4 + 2×R8i (continued)
Dimensions
150
Dimensions
151
Frame size 1×D4 + 2×R8i (with a main switch-disconnector +F253)
Dimensions
152
Frame size 1×D4 + 2×R8i (with +F253) (continued)
Dimensions
153
Dimensions
154
Dimensions
155
Dimensions
156
Dimensions
157
Frame size 1×D4 + 2×R8i (with top entry/exit)
Dimensions
158
Frame size 1×D4 + 2×R8i (with top entry/exit) (continued)
Dimensions
159
Frame size 1×D4 + 2×R8i (with top entry/exit) (continued)
Dimensions
160
Dimensions
161
Dimensions
162
Dimensions
163
Dimensions
164
Dimensions
165
Dimensions
166
Dimensions
167
Dimensions
168
Dimensions
169
Dimensions
170
Frame size 2×D4 + 3×R8i (with +F253)
Dimensions
171
Dimensions
172
Dimensions
173
Frame size 2×D4 + 3×R8i (with a main breaker +F255)
Dimensions
174
Dimensions
175
Dimensions
176
Dimensions
177
Dimensions
178
Dimensions
179
Dimensions
180
Dimensions
181
Frame size 3×D4 + 4×R8i (with a main breaker +F255)
Dimensions
182
Dimensions
183
Dimensions
184
Dimensions
185
Common motor terminal cubicle

Depending on the drive size, the common motor terminal cubicle is either 300, 400
or 600 mm wide. Refer to the cabinet line-up tables at the beginning of this chapter.
Dimensions
186
300 mm
Dimensions
187
400 mm
Dimensions
188
600 mm
Dimensions
189
Resistor braking

This chapter describes the resistor braking options of the ACS800-07 (+V992).
Resistor braking options

The following ACS800-07 (>500 kW) drives are available with brake choppers and
resistors.
UN ACS800-07 (+V992) Brake chopper type (+D150) Brake resistor type (+D151)
type
ACS800-07-0610-3 2 × NBRA-659 2 × (2 × SAFUR180F460)
ACS800-07-0770-3 2 × NBRA-659 2 × (2 × SAFUR180F460)

400 V
ACS800-07-0870-3 3 × NBRA-659 3 × (2 × SAFUR180F460)
ACS800-07-1030-3 3 × NBRA-659 3 × (2 × SAFUR180F460)
ACS800-07-0760-5 2 × NBRA-659 2 × (2 × SAFUR200F500)
ACS800-07-0910-5 2 × NBRA-659 2 × (2 × SAFUR200F500)

500 V
ACS800-07-1090-5 3 × NBRA-659 3 × (2 × SAFUR200F500)
ACS800-07-1210-5 3 × NBRA-659 3 × (2 × SAFUR200F500)
ACS800-07-0750-7 2 × NBRA-669 2 × (2 × SAFUR200F500)
ACS800-07-0870-7 2 × NBRA-669 2 × (2 × SAFUR200F500)

690 V
ACS800-07-1060-7 3 × NBRA-669 3 × (2 × SAFUR200F500)
ACS800-07-1160-7 3 × NBRA-669 3 × (2 × SAFUR200F500)
Resistor braking
190
Chopper/Resistor combinations – Technical data

The following table contains the technical data of some chopper/resistor
combinations.
Duty Cycle Duty Cycle
(10/60 s) (1/5 min)
R Pbrmax Pcont Imax
UN Chopper(s) Resistors
(ohm) (kW) (kW) (A)
Pbr Irms Pbr Irms
(kW) (A) (kW) (A)
1 × NBRA-659 2 × SAFUR180F460 1.2 353 54 545 287 444 167 257
400 V 2 × NBRA-659 2 × (2 × SAFUR180F460) 1.2 706 108 1090 575 888 333 514
3 × NBRA-659 3 × (2 × SAFUR180F460) 1.2 1058 162 1635 862 1332 500 771
1 × NBRA-659 2 × SAFUR200F500 1.35 403 54 605 287 355 167 206
500 V 2 × NBRA-659 2 × (2 × SAFUR200F500) 1.35 806 108 1210 575 710 333 412
3 × NBRA-659 3 × (2 × SAFUR200F500) 1.35 1208 162 1815 862 1065 500 618
1 × NBRA-669 2 × SAFUR200F500 1.35 404 54 835 287 257 167 149
690 V 2 × NBRA-669 2 × (2 × SAFUR200F500) 1.35 807 108 1670 575 514 333 298
3 × NBRA-669 3 × (2 × SAFUR200F500) 1.35 1211 162 2505 862 771 500 447
UN = Nominal voltage
R = Resistance of specified resistors (per chopper)
Pbrmax = Maximum short-term (1 min every 10 mins) braking power
Pcont = Maximum continuous braking power
Imax = Maximum peak current
Pbr = Braking power for the specified duty cycle
Irms = Corresponding RMS current
Brake resistors – Technical data

The following table contains the technical data for the resistors supplied by ABB.
UN R ER PRcont
Type
(V) (ohm) (kJ) (kW)
SAFUR125F500 500 4.0 3600 9.0
SAFUR210F575 575 3.4 4200 10.5
SAFUR200F500 500 2.7 5400 13.5
SAFUR180F460 460 2.4 6000 15.0
UN Nominal voltage
R Resistance
ER Short energy pulse that the resistor assembly will withstand each 400 seconds
PRcont Continuous power (heat) dissipation of the resistor when placed correctly. Energy ER dissipates in 400
seconds.
Resistor braking
191
Verifying the capacity of the braking equipment

1. Calculate the maximum power (Pmax) generated by the motor during braking.
2. Ensure the following condition is met:
Pbrmax > Pmax
The Pbrmax values specified in the technical data table above are for the reference braking cycle
(1 minute of braking, 9 minutes of rest). If the actual duty cycle does not correspond to the reference
cycle, the maximum allowed braking power Pbr must be used instead. In the technical data table,
Pbr is given for two additional braking cycles. See below for directions for calculating Pbr for other
braking cycles.
3. Check the resistors selection. The energy generated by the motor during a 400-
second period must not exceed the heat dissipation capacity ER.
If the ER value is not sufficient, it is possible to use a four-resistor assembly in which two standard
resistors are connected in parallel, two in series. The ER value of the four-resistor assembly is four
times the value specified for the standard resistor.
Custom resistors
Resistors other than the standard resistors can be used provided that:
• the resistance is not lower than with the standard resistors
WARNING! Never use a brake resistor with a resistance below the value specified
for the particular drive / brake chopper / resistor combination. The drive and the
chopper are not able to handle the overcurrent caused by the low resistance.
• the resistance does not restrict the braking capacity needed, ie,
2
UDC
Pmax <
R
where
Pmax maximum power generated by the motor during braking
UDC voltage over the resistor during braking, for example,
1.35 · 1.2 · 415 VDC (when supply voltage is 380 to 415 VAC),
1.35 · 1.2 · 500 VDC. (when supply voltage is 440 to 500 VAC) or
1.35 · 1.2 · 690 VDC (when supply voltage is 525 to 690 VAC).
R resistor resistance (ohm)
• the heat dissipation capacity (ER) of the resistors is sufficient for the application
(see step 3 above).
Resistor braking
192
Calculating the maximum braking power (Pbr)

• Braking energy transferred during any ten minute period must be less than or
equal to the energy transferred during the reference braking cycle.
• The braking power must not exceed the rated maximum value Pbrmax.
1. n x Pbr x tbr < Pbrmax x 60 s

2. Pbr < Pbrmax
n = Number of braking pulses during

a ten minute period
Pbr = Maximum allowed braking power (kW).
tbr = Braking time (s)
Pbrmax = Maximum Braking Power
for a reference cycle (kW)
Example 1
Duration of a braking cycle is 30 minutes. The braking time is
15 minutes.
Result: If the braking time exceeds 10 minutes, the braking is considered
continuous. The allowed continuous braking power is 10% of the Maximum Braking
Power (Pbrmax).
Example 2
Duration of a braking cycle is three minutes. The braking time is
40 seconds.
Pbrmax x 60 s
1. Pbr < = 0.375 x Pbrmax
4 x 40 s
Pbr
Pbrmax
t
tbr 600 s
T = Duration of braking cycle
2. Pbr < Pbrmax O.K.
Result: The maximum allowed braking power for the cycle is 37% of the rated value
given for the reference cycle.
Resistor braking
193
Example 3
Duration of a braking cycle is three minutes. The braking time is 10 seconds.
Pbrmax x 60 s
1. Pbr < = 1.5 · Pbrmax
4 x 10 s
Pbr
Pbrmax
t
tbr 600 s
T = Duration of the braking cycle
2. Pbr > Pbrmax Not allowed.
Result: The maximum allowed braking power for the cycle is equal to the Maximum
Braking Power (Pbrmax) given for the reference cycle.
Resistor braking
194
Custom resistor installation and wiring

Effective cooling of the resistors must be ensured.
WARNING! All materials near the brake resistors must be non-flammable. The
surface temperature of the resistors is high. The temperature of the air rising from
the resistors is hundreds of degrees Celsius. Protect the resistors against contact.
For a resistor cable, use a shielded cable. The maximum length of the resistor cable
is 10 m.
A recommended copper cable size for connecting the user-defined resistor to the
brake unit is as follows:
• 400 V brake unit: 3 x 95 mm2 + 50 mm2
For protection against overheating, resistors with thermal circuit breakers (standard
in ABB resistors) should be used. The circuit breakers should be wired to the
ENABLE inputs of the brake choppers.
WARNING! The ENABLE input terminal blocks of the choppers are at intermediate
circuit potential when the supply unit of the ACS800-07 (+V992) drive is running.
This voltage is extremely dangerous and may cause serious damage or injuries if the
isolation level and protection conditions for the thermal circuit breakers are not
sufficient. The normally-closed breakers should always be properly isolated (over
2.5 kV) and shrouded against contact.
Note: For the ENABLE input wiring, use a cable rated as follows:
• twisted pair (screened type recommended)
• rated operating voltage between a core and earth (U0): ≥ 750 V
• insulation test voltage > 2.5 kV.
Resistor braking
195
The following is a wiring diagram example of the resistor connection.
Brake chopper
X1
R+ R‚ 1 2
1 2 3
R+ R‚
t°
Brake resistor
Brake circuit commissioning

In the drive application program, overvoltage control of the drive must be disabled for
correct operation of the brake chopper. Check the drive parameter setting at the start
up.
Resistor braking
196
Resistor braking
a
b
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.
Providing feedback on ABB Drives manuals

Your comments on our manuals are welcome. Go to www.abb.com/drives and select Document
Library – Manuals feedback form (LV AC drives).
Document library on the Internet

You can find manuals and other product documents in PDF format on the Internet. Go to
www.abb.com/drives and select Document Library. You can browse the library or enter selection
criteria, for example a document code, in the search field.
3AUA0000068936 Rev A / EN
EFFECTIVE: 2010-03-15
ABB Oy ABB Inc. ABB Beijing Drive Systems Co. Ltd.

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

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What this chapter contains

Usage of warnings and notes

Dangerous voltage warning warns of high voltages which can cause

General warning warns about conditions, other than those caused by

Installation and maintenance work

• Apply temporary grounding before working on the unit.

• After maintaining or modifying a drive safety circuit or changing circuit boards

• The main disconnecting device (main breaker or main switch-disconnector)

• The brake control terminals (UDC+, UDC-, R+ and R- terminals) carry a

• Depending on the external wiring, dangerous voltages (115 V, 220 V or 230 V)

• During the installation procedure, the inverter modules may have to be

• Fastening the cabinet by riveting or welding is not recommended. However, if

• Ensure sufficient cooling of the unit.

• Some parts inside the drive cabinet, such as heatsinks of power

• The printed circuit boards contain components sensitive to electrostatic

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

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

• Do not install a drive equipped with an EMC (line) filter to an ungrounded

• As the normal leakage current of the drive is higher than 3.5 mA AC or

Fibre optic cables

• Close the switch fuses of all parallel-connected inverters before start.

Permanent magnet motor drives

Installation and maintenance work

About this manual

Other operating switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Planning the electrical installation

Protection against short-circuit inside the drive or in the supply cable . . . . . . . . . . . . . . . . . 62

or main breaker (option +F253 or +F255) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

Motor control and I/O board (RMIO)

Installation checklist and start-up

On-load checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132

About this manual

What this chapter contains

Categorization according to the frame size

About this manual

About this manual

Installation and commissioning flowchart

Plan the installation. Technical data

Only intact units may be started up.

Check the installation site. Mechanical installation, Technical data

Route the cables. Planning the electrical installation: Routing the

Mount the cabinet line-up. Mechanical installation

Check the installation. Installation checklist and start-up

Commission the drive. Installation checklist and start-up

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

About this manual

Terms and abbreviations

ADPI Control panel interface board

BAMU Main voltage measurement board

CDP312R Control panel

CINT Module interface board

CMIB Interface board to the main circuit thyristors and current

CVAR Varistor board

Diode supply module See supply module

DSU module Diode supply module