ACS800

SELLER DOCUMENT REVIEW

Permission to proceed does not constitute acceptance or approval of design detail, calculations,
analysis, test methods, or materials developed or selected by SELLER, and does not relieve SELLER from full compliance with
contractual obligation.

Document Status: 4
1 Work may proceed 4 Review not required. Work may
proceed

Revise & Resubmit. Work may proceed

2
subject to incorporation of changes 5 Cancelled / Superseded

3 Revise & Resubmit. Work may NOT proceed

Reviewer Name: Acevedo_Torres_Carmen Date: 12/12/12

Discipline: EE - Electrical Document Number:25713-220-V1A-EVV1-00015

Hardware Manual
Equipment No:
NA
Submittal Number: 001

ACS800-31 Drives (5.5 to 110 kW)

ACS800-U31 Drives (7.5 to 125 HP)

ACS800 Single Drive Manuals

HARDWARE MANUALS (appropriate manual is included in the

delivery)

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

3AFE64382101 (English)

ACS800-01/U1 Marine Supplement 3AFE64291275 (English)

ACS800-02/U2 Hardware Manual 90 to 500 kW (125 to 600 HP)

3AFE64567373 (English)

ACS800-11/U11 Hardware Manual 5.5 to110 kW (7.5 to 125 HP)

3AFE68367883 (English)

ACS800-31/U31 Hardware Manual 5.5 to110 kW (7.5 to 125 HP)

3AFE68599954 (English)

ACS800-04 Hardware Manual 0.55 to 132 kW

3AFE68372984 (English)

ACS800-04/04M/U4 Hardware Manual 45 to 560 kW (60 to

600 HP) 3AFE64671006 (English)

ACS800-04/04M/U4 Cabinet Installation 45 to 560 kW (60 to

600 HP) 3AFE68360323 (English)

ACS800-07/U7 Hardware Manual 45 to 560 kW (50 to 600 HP)

3AFE64702165 (English)

ACS800-07/U7 Dimensional Drawings 45 to 560 kW (50 to

600 HP) 3AFE64775421

ACS800-07 Hardware Manual 500 to 2800 kW

3AFE64731165 (English)

ACS800-17 Hardware Manual 75 to 1120 kW

3AFE64681338 (English)

ACS800-37 Hardware Manual 160 to 2800 kW (200 to 2700 HP)

3AFE68557925 (English)

• Safety instructions

• Electrical installation planning

• Mechanical and electrical installation

• Motor control and I/O board (RMIO)

• Maintenance

• Technical data

• Dimensional drawings

• Resistor braking

FIRMWARE MANUALS, SUPPLEMENTS AND GUIDES

(appropriate documents are included in the delivery)

Standard Application Program Firmware Manual

3AFE64527592 (English)

System Application Program Firmware Manual

3AFE63700177 (English)

Application Program Template Firmware Manual

3AFE64616340 (English)

Master/Follower 3AFE64590430 (English)

Pump Control Application Program Firmware Manual

3AFE68478952 (English)

Extruder Control Program Supplement 3AFE64648543 (English)

Centrifuge Control Program Supplement 3AFE64667246 (English)

Traverse Control Program Supplement 3AFE64618334 (English)

Crane Control Program Firmware Manual 3BSE11179 (English)

Adaptive Programming Application Guide

3AFE64527274 (English)

OPTION MANUALS (delivered with optional equipment)

Fieldbus Adapters, I/O Extension Modules etc.

 ACS800-31 Drives

5.5 to 110 kW

ACS800-U31 Drives

7.5 to 125 HP

Hardware Manual

3AFE68599954 Rev A EN

EFFECTIVE: 14.10.2005

© 2005 ABB Oy. All Rights Reserved.

 1

Update Notice

The notice concerns the following ACS800-31 Drives (5.5

Code: 3AUA0000059448 Rev B

to 110 kW) and ACS800-U31 Drives (7.5 to 125 HP)

Valid: from 01.09.2010 until the release of the next revision of

Hardware Manuals:
the manual

Code Revision Language

Contents:

3AFE68599954 A English EN
The headings in this update notice refer to the modified

3AFE68626552 A German DE
subsections in the original English manual. Each heading also

includes a page number and a classifier NEW, CHANGED, or

3AFE68626561 A French FR DELETED. The page number refers to the page number in the

original English manual. The classifier describes the type of

the modification.

NEW (page 6): Safety / Installation and maintenance work

• 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.

[...]

Note:

• The Safe torque off function (option +Q967) does not remove the voltage from the

main and auxiliary circuits.

NEW (page 10): Safety / Operation

• The Safe torque off function (option +Q967) can be used for stopping the drive in

emergency stop situations. In the normal operating mode, use the Stop command

instead.

NEW (page 20): Contents

• Installation of ASTO board (Safe torque off, +Q967) describes the electrical

installation of the optional Safe torque off function.

CHANGED (page 22): Installation and commissioning flowchart

See Electrical installation, Motor control and I/O board (RMIO), Installation of AGPS

board (Prevention of Unexpected Start, +Q950), Installation of ASTO board (Safe

torque off, +Q967) and the optional module manual delivered with the module.

Update Notice

NEW (page 31): Type code

The table below contains the new option code definition for the Safe torque off

function.

Code Description

+Q967 Safe torque off (STO)

NEW (page 49): Emergency stop

Note: If you add or modify the wiring in the drive safety circuits, ensure that the

appropriate standards (e.g. IEC 61800-5-1, EN 62061, EN/ISO 13849-1 and -2) and

the ABB guidelines are met. After making the changes, verify the operation of the

safety function by testing it.

NEW (page 51 ): 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, IEC 61508, and EN 62061:2005. The

function also corresponds to an uncontrolled stop in accordance with category 0 of

EN 60204-1 and prevention of unexpected start-up of EN 1037.

The STO may be used where power removal is required to prevent an unexpected

start. The 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.

Update Notice

Update Notice

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: The Safe torque off function can be used for stopping the drive in emergency

stop situations. In the normal operating mode, use the Stop command instead. If a

running drive is stopped by using the function, the drive will trip and stop by coasting.

If this is not acceptable, e.g. causes danger, the drive and machinery must be

stopped using the appropriate stopping mode before using this function.

Note concerning permanent magnet motor drives in case of a multiple IGBT

power semiconductor failure: In spite of the activation of the Safe torque off

function, the drive system can produce an alignment torque which maximally rotates

the motor shaft by 180/p degrees. p denotes the pole pair number.

Note: If you add or modify the wiring in the drive safety circuits, ensure that the

appropriate standards (e.g. IEC 61800-5-1, EN 62061, EN/ISO 13849-1 and -2) and

the ABB guidelines are met. After making the changes, verify the operation of the

safety function by testing it.

NEW (page 75): Installation of ASTO board (Safe torque off, +Q967)

What this chapter contains

This chapter describes

• electrical installation of the optional Safe torque off function (+Q967) of the drive.

• specifications of the board.

Safe torque off (+Q967)

The optional Safe torque off function includes an ASTO board, which is connected to

the drive and an external power supply. See also chapter Planning the electrical

installation, page 50.

Installation of the ASTO board

WARNING! Dangerous voltages can be present at the ASTO board even when the

24 V supply is switched off. Follow the Safety instructions on the first pages of this

manual and the instruction in this chapter when working on the ASTO board.

Make sure that the drive is disconnected from the mains (input power) and the

24 V source for the ASTO board is switched off during installation and

maintenance. If the drive is already connected to the mains, wait for 5 min after

disconnecting mains power.

Update Notice

See

• page 24 for location of terminal block X41 of the drive

• page 6 (in this Update Notice) for the circuit diagram

• page 6 (in this Update Notice) for the dimensions of the ASTO-11C board

• section ASTO-11C in chapter Technical data for the technical data of the ASTO-

11C board.

Note: Maximum cable length between ASTO terminal block X2 and the drive

terminal block is restricted to 3 metres.

Connect the ASTO board as follows:

• Remove the cover of the enclosed ASTO unit by undoing the fixing screws (1).

• Ground the ASTO unit via the bottom plate of the enclosure or via terminal X1:2

or X1:4 of the ASTO board.

• Connect the cable delivered with the kit between terminal block X2 of the ASTO

board (2) and drive terminal block X41.

• Connect a cable between connector X1 of the ASTO board (3) and the 24 V

source.

• Fasten the cover of the ASTO unit back with screws.

X2

X1

24 V
3

Update Notice

Circuit diagram

The diagram below shows the connection between the ASTO board and the drive

when it is ready. For an example diagram of a complete Safe torque off circuit, see

page 3 (in this Update Notice).

3AUA0000069101

Dimensions

The dimensions of the ASTO board are the same as the dimensions of the AGPS

board. See Dimensional drawing on page 74.

NEW (page 111): ASTO-11C

Nominal input voltage 24 V DC

Nominal input current 40 mA (20mA per channel)

X1 terminal sizes 4 x 2.5 mm

2

Nominal output current 0.4 A

X2 terminal block type JST B4P-VH

Ambient temperature 0...50°C

Relative humidity Max. 90%, no condensation allowed

Dimensions (with
167 x 128 x 52 mm (Height x Weight x Depth)

enclosure)

Weight (with enclosure) 0.75 kg

Update Notice

NEW (page 111): Ambient conditions

Modules with option +Q967: the installation site altitude in operation is 0 to 2000 m.

Operation

installed for stationary use

Installation site altitude

[...]

Modules with option +Q967

: 0 to 2000 m

Update Notice

Update Notice

Safety instructions

What this chapter contains

This chapter contains the safety instructions which you must follow when installing,

operating and servicing the drive. If ignored, physical injury or death may follow, or

damage may occur to the drive, motor or driven equipment. Read the safety

instructions before you work on the unit.

To which products this chapter applies

This chapter applies to the ACS800-01/U1, ACS800-11/U11, ACS800-31/U31,

ACS800-02/U2 and ACS800-04/04M/U4 of frame sizes R7 and R8.

Use of warnings and notes

There are two types of safety instructions throughout this manual: warnings and

notes. Warnings caution you about conditions which can result in serious injury or

death and/or damage to the equipment. They also tell you how to avoid the danger.

Notes draw attention to a particular condition or fact, or give information on a

subject. The warning symbols are used as follows:

Dangerous voltage warning warns of high voltage which can cause

physical injury and/or damage to the equipment.

General warning warns about conditions, other than those caused by

electricity, which can result in physical injury and/or damage to the

equipment.

Electrostatic discharge warning warns of electrostatic discharge which

can damage the equipment.

Safety instructions

Installation and maintenance work

These warnings are intended for all who work on the drive, motor cable or motor.

WARNING! Ignoring the following instructions can cause physical injury or death, or

damage to the equipment:

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

•
Never work on the drive, motor cable or motor when main power is applied.

After disconnecting the input power, always wait for 5 min to let the intermediate

circuit capacitors discharge before you start working on the drive, motor or

motor cable.

Always ensure by measuring with a multimeter (impedance at least 1 Mohm)

that:

1. voltage between drive input phases U1, V1 and W1 and the frame is close to

0 V.

2. voltage between terminals UDC+ and UDC- and the frame is close to 0 V.

•
Do not work on the control cables when power is applied to the drive or to the

external control circuits. Externally supplied control circuits may cause

dangerous voltages inside the drive even when the main power on the drive is

switched off.

•
Do not make any insulation or voltage withstand tests on the drive or drive

modules.

•
When reconnecting the motor cable, always check that the phase order is

correct.

Note:

•
The motor cable terminals on the drive are at a dangerously high voltage when

the input power is on, regardless of whether the motor is running or not.

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

dangerous DC voltage (over 500 V).

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

may be present on the terminals of relay outputs RO1 to RO3.

•
ACS800-02 with enclosure extension: The main switch on the cabinet door

does not remove the voltage from the input busbars of the drive. Before working

on the drive, isolate the whole drive from the supply.

•
ACS800-04M, ACS800-07: The Prevention of Unexpected Start function does

not remove the voltage from the main and auxiliary circuits.

•
At installation sites above 2000 m (6562 ft), the terminals of the RMIO board

and optional modules attached to the board do not fulfil the Protective Extra

Low Voltage (PELV) requirements stated in EN 50178.

Safety instructions

Grounding

These instructions are intended for all who are responsible for the grounding of the

drive.

WARNING! Ignoring the following instructions can cause physical injury, death,

increased electromagnetic interference and equipment malfunction:

•
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).

•
ACS800-01, ACS800-11, ACS800-31: In European CE compliant installations

and in other installations where EMC emissions must be minimized, make a

360° high frequency grounding of cable entries in order to suppress

electromagnetic disturbances. In addition, connect the cable shields to

protective earth (PE) in order to meet safety regulations.

ACS800-04 (45 to 560 kW) and ACS800-02 in first environment: make a 360°

high frequency grounding of motor cable entries at the cabinet lead-through.

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

ACS800-01 and ACS800-11, ACS800-31 only) on an ungrounded power

system or a high-resistance-grounded (over 30 ohms) power system.

Note:

•
Power cable shields are suitable for equipment grounding conductors only

when adequately sized to meet safety regulations.

•
As the normal leakage current of the drive is higher than 3.5 mA AC or 10 mA

DC (stated by EN 50178, 5.2.11.1), a fixed protective earth connection is

required.

Safety instructions

Mechanical installation and maintenance

These instructions are intended for all who install and service the drive.

WARNING! Ignoring the following instructions can cause physical injury or death,

or damage to the equipment:

•
Handle the unit carefully.

•
ACS800-01, ACS800-11, ACS800-31: The drive is heavy. Do not lift it alone.

Do not lift the unit by the front cover. Place the unit only on its back.

ACS800-02, ACS800-04: The drive is heavy. Lift the drive by the lifting lugs

only. Do not tilt the unit. The unit will overturn from a tilt of about 6 degrees.

Use extreme caution when manoeuvring a drive that runs on wheels. An

overturning unit can cause physical injury.

Do not tilt!

•
Beware of hot surfaces. Some parts, such as heatsinks of power

semiconductors, remain hot for a while after disconnection of the electrical

supply.

•
Make sure that dust from drilling does not enter the drive when installing.

Electrically conductive dust inside the unit may cause damage or

malfunctioning.

•
Ensure sufficient cooling.

•
Do not fasten the drive by riveting or welding.

Safety instructions

Printed circuit boards

WARNING! Ignoring the following instructions can cause damage to the printed

circuit boards:

•
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.

Fibre optic cables

WARNING! Ignoring the following instructions can cause equipment malfunction

and damage to the fibre optic cables:

•
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 in.).

Safety instructions

10

Operation

These warnings are intended for all who plan the operation of the drive or operate

the drive.

WARNING! Ignoring the following instructions can cause physical injury or death,

or damage to the equipment:

•
Before adjusting the drive and putting it into service, make sure that the motor

and all driven equipment are suitable for operation throughout the speed range

provided by the drive. The drive can be adjusted to operate the motor at

speeds above and below the speed provided by connecting the motor directly

to the power line.

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

Program if dangerous situations can occur. When activated, these functions

will reset the drive and resume operation after a fault.

•
Do not control the motor with the disconnecting device (disconnecting means);

instead, use the control panel keys and , or commands via the I/O

board of the drive. The maximum allowed number of charging cycles of the DC

capacitors (i.e. power-ups by applying power) is five in ten minutes.

•
ACS800-04M, ACS800-07: Do not use the optional Prevention of Unexpected

Start function for stopping the drive when the drive is running. Give a Stop

command instead.

Note:

•
If an external source for start command is selected and it is ON, the drive (with

Standard Application Program) will start immediately after fault reset unless the

drive is configured for 3-wire (a pulse) start/stop.

•
When the control location is not set to Local (L not shown in the status row of

the display), the stop key on the control panel will not stop the drive. To stop

the drive using the control panel, press the LOC/REM key and then the stop

key .

Safety instructions

 11

Permanent magnet motor

These are additional warnings concerning permanent magnet motor drives. Ignoring

the instructions can cause physical injury or death, or damage to the equipment.

Installation and maintenance work

WARNING! Do not work on the drive when the permanent magnet motor is rotating.

Also, when the supply power is switched off and the inverter is stopped, a rotating

permanent magnet motor feeds power to the intermediate circuit of the drive and the

supply connections become live.

Before installation and maintenance work on the drive:

• Stop the motor.

• Ensure that the motor cannot rotate during work.

• Ensure that there is no voltage on the drive power terminals:

Alternative 1) Disconnect the motor from the drive with a safety switch or by other

means. Measure that there is no voltage present on the drive input or output

terminals (U1, V1, W1, U2, V2, W2, UDC+, UDC-).

Alternative 2) Measure that there is no voltage present on the drive input or output

terminals (U1, V1, W1, U2, V2, W2, UDC+, UDC-). Ground the drive output

terminals temporarily by connecting them together as well as to the PE.

Alternative 3) If possible, both of the above.

Start-up and operation

WARNING! Do not run the motor over the rated speed. Motor overspeed leads to

overvoltage which may damage or explode the capacitors in the intermediate circuit

of the drive.

Controlling a permanent magnet motor is only allowed using the ACS800 Permanent

Magnet Synchronous Motor Drive Application Program, or other application

programs in scalar control mode.

Safety instructions

12

Safety instructions

 13

Table of contents

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

Safety instructions

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

To which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Mechanical installation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Fibre optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Permanent magnet motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Start-up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Table of contents

About this manual

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Common chapters for several products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Categorization according to the frame size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Categorization according to the plus code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Installation and commissioning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

The ACS800-31/U31

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

The ACS800-31/U31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Line-side converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Motor-side converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

AC voltage and current waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

DDCS communication modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Main circuit and control interfaces diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Fieldbus control of the line-side converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Control block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Connection diagram of the RMIO board in the line-side converter . . . . . . . . . . . . . . . . . . . . . . . . . 30

Table of contents

14

Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Mechanical installation

Unpacking the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Moving the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Requirements for the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Free space around the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Mounting the drive on the wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Units without vibration dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Units with vibration dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Cabinet installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Preventing cooling air recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Unit above another . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Planning the electrical installation

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

To which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Motor selection and compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Permanent magnet synchronous motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Supply connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Disconnecting device (disconnecting means) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

ACS800-01, ACS800-U1, ACS800-11, ACS800-U11, ACS800-31, ACS800-U31, ACS800-02

and ACS800-U2 without enclosure extension, ACS800-04, ACS800-U4 . . . . . . . . . . . . . . . 45

ACS800-02 and ACS800-U2 with enclosure extension, ACS800-07 and ACS800-U7 . . . . 45

EU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

US . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Thermal overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Ground fault protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Emergency stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

ACS800-02/U2 with enclosure extension and ACS800-07/U7 . . . . . . . . . . . . . . . . . . . . . . . . . 49

Restarting after an emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Prevention of Unexpected Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

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 15

Power factor compensation capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Equipment connected to the motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Installation of safety switches, contactors, connection boxes, etc. . . . . . . . . . . . . . . . . . . . . . . . 54

Bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Before opening a contactor (DTC control mode selected) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Protecting the relay output contacts and attenuating disturbances in case of inductive loads . . . . 55

Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Connection of a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Installation sites above 2000 metres (6562 feet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Electrical installation

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Checking the insulation of the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Input cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Disconnecting the EMC filter capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Conductor stripping lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Allowed wire sizes, tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Wall installed units (European version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Power cable installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Wall installed units (US version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Warning sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Cabinet installed units (IP 00, UL type open) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

360 degrees grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

When the outer surface of the shield is covered with non-conductive material . . . . . . . . . . . 68

Connecting the shield wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Cabling of I/O and fieldbus modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Pulse encoder module cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Fastening the control cables and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Installation of optional modules and PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Installation of AGPS board (Prevention of Unexpected Start, +Q950)

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Prevention of Unexpected Start (+Q950) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Installation of the AGPS board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Dimensional drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

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16

Motor control and I/O board (RMIO)

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

To which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Note for the ACS800-02 with enclosure extension and the ACS800-07 . . . . . . . . . . . . . . . . . . . . 75

Note on terminal labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Note on external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

External control connections (non-US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

External control connections (US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

RMIO board specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Analogue inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Constant voltage output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Auxiliary power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Analogue outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

DDCS fibre optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

24 VDC power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Installation checklist

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Start-up and use

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Start-up and use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

To control the line-side converter... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

To control the motor-side converter... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Actual signals and parameters

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Line-side converter actual signals and parameters in the motor-side converter application

program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Actual signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

09 ACTUAL SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

95 HARDWARE SPECIF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

ACS800-31/U31 specific parameters in the IGBT Supply Control Program . . . . . . . . . . . . . . . . . 91

Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

16 SYSTEM CTR INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

31 AUTOMATIC RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Fixed parameters with the ACS800-31 and ACS800-U31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

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Maintenance

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Main cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Fan replacement (R5, R6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Additional fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Replacement (R5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Replacement (R6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Fault tracing

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Faults and warnings displayed by the CDP-312R Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Warning/Fault message from unit not being monitored by control panel . . . . . . . . . . . . . . . . . . 99

Conflicting ID numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Technical data

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

IEC data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Mains cable fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Cable entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Dimensions, weights and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

NEMA data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Input cable fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Cable Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Dimensions, weights and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Input power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

AGPS-11C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Table of contents

18

Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Compliance with the EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Compliance with the EN 61800-3 (2004) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

First environment (drive of category C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Second environment (drive of category C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Second environment (drive of category C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

“C-tick” marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Compliance with IEC 61800-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

First environment (drive of category C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Second environment (drive of category C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Second environment (drive of category C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

UL/CSA markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

UL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Equipment warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Dimensional drawings

Frame size R5 (IP21, UL type open, UL type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Frame size R6 (IP21, UL type open, UL type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Resistor braking

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

How to select the correct drive/chopper/resistor combination . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

External brake chopper and resistor(s) for the ACS800-31/U31 . . . . . . . . . . . . . . . . . . . . . . . . . 124

Brake chopper and resistor installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Brake circuit commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

External +24 V power supply for the RMIO boards via terminal X34

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Connecting +24 V external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

RMIO board of the motor-side converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

RMIO board of the line-side converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Frame size R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Frame size R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Table of contents

 19

About this manual

What this chapter contains

This chapter describes the intended audience and contents of this manual. It

contains a flowchart of steps in checking the delivery, installing and commissioning

the drive. The flowchart refers to chapters/sections in this manual and other

manuals.

Intended audience

This manual is intended for people who plan the installation, install, commission, use

and service the drive. Read the manual before working on the drive. The reader is

expected to know the fundamentals of electricity, wiring, electrical components and

electrical schematic symbols.

This manual is written for readers worldwide. Both SI and imperial units are shown.

Special US instructions for installations within the United States that must be

installed per the National Electrical Code and local codes are marked with (US).

Common chapters for several products

Chapters Safety instructions, Planning the electrical installation and Motor control

and I/O board (RMIO) apply to several ACS800 products which are listed at the

beginning of the chapters.

Categorization according to the frame size

Some instructions, technical data and dimensional drawings which concern only

certain frame sizes are marked with the symbol of the frame size R2, R3, ... or R8.

The frame size is not marked on the drive designation label. To identify the frame

size of your drive, see the rating tables in chapter Technical data.

The ACS800-31/U31 is manufactured in frame sizes R5 and R6.

Categorization according to the plus code

The instructions, technical data and dimensional drawings which concern only

certain optional selections are marked with plus codes, e.g. +E202. The options

included in the drive can be identified from the plus codes visible on the type

designation label of the drive. The plus code selections are listed in chapter The

ACS800-31/U31 under Type code.

About this manual

20

Contents

The chapters of this manual are briefly described below.

Safety instructions give safety instructions for the installation, commissioning,

operation and maintenance of the drive.

About this manual lists the steps in checking the delivery and installing and

commissioning the drive and refers to chapters/sections in this manual and other

manuals for particular tasks.

The ACS800-31/U31 describes the drive.

Mechanical installation instructs in how to place and mount the drive.

Planning the electrical installation instructs in the motor and cable selection,

protections and cable routing.

Electrical installation shows how to wire the drive.

Installation of AGPS board (Prevention of Unexpected Start, +Q950) describes the

electrical installation of the optional Prevention of Unexpected Start function

(+Q950).

Motor control and I/O board (RMIO) shows the external control connections to the

I/O board.

Installation checklist contains a list for checking the mechanical and electrical

installation of the drive.

Start-up and use describes the start-up procedure and use of the drive.

Actual signals and parameters contains listings of parameters specific to the

ACS800-31 and ACS800-U31.

Maintenance contains preventive maintenance instructions.

Fault tracing contains guide lines for fault tracing.

Technical data contains the technical specifications of the drive, e.g. the ratings,

sizes and technical requirements, provisions for fulfilling the requirements for CE

and other markings and warranty policy.

Dimensional drawings contains the dimensional drawings of the drive.

Resistor braking describes how to select, protect and wire external brake choppers

and resistors for the drive. The chapter also contains installation instructions and the

technical data.

External +24 V power supply for the RMIO boards via terminal X34 describes how to

connect an external +24 V power supply for the RMIO board using terminal X34.

About this manual

 21

Installation and commissioning flowchart

Task See

Identify the frame size of your drive: R5 or R6. Technical data /IEC data or NEMA data

Plan the installation.

Technical data

Check the ambient conditions, ratings, required

Planning the electrical installation

cooling air flow, input power connection, compatibility

For compliance with the European Union EMC

of the motor, motor connection, and other technical

Directive, see Technical data: CE marking.

data.

Select the cables.

Option manual (if optional equipment is

included)

Unpack and check the units.

Mechanical installation: Unpacking the unit.

Check that all necessary optional modules and

If the converter has been non-operational for

equipment are present and correct.

more than one year, the converter DC link

Only intact units may be started up.

capacitors need to be reformed. Ask ABB for

instructions.

If the drive is about to be connected to an IT

The ACS800-31/U31: Type code; Electrical

(ungrounded) system, check that the drive is not

installation: IT (ungrounded) systems.

equipped with EMC filtering intended for grounded

systems.

Check the installation site. Mechanical installation: Before installation

Technical data

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

Route the cables. Planning the electrical installation: Routing the

cables

For compliance with the European Union EMC

Directive, see Technical data: CE marking.

About this manual

22

Task See

Check the insulation of the motor and the motor

Electrical installation: Checking the insulation of

cable.
the installation

Connect the power cables. Electrical installation

Connect the control and auxiliary control cables. Electrical installation, Motor control and I/O

board (RMIO), Installation of AGPS board

(Prevention of Unexpected Start, +Q950) and

the optional module manual delivered with the

module.

Check the installation. Installation checklist

Commission the drive. Start-up and use, appropriate application

program firmware manual

Inquiries

Address any inquiries about the product to the local ABB representative, quoting the

type code and serial number of the unit. If the local ABB representative cannot be

contacted, address inquiries to the manufacturing facility.

About this manual

 23

The ACS800-31/U31

What this chapter contains

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

The ACS800-31 /U31

The ACS800-31/U31 is wall mountable, low-harmonic drive for controlling AC

motors.

IP21 (UL type 1)

IP20 (UL type open)

Cooling fan

Top cover

Control panel

CDP312R

Heat sink

Front cover

Clear plastic

shroud

Connection box cover

Frame size R6

The ACS800-31/U31

24

UDC+

UDC-

I/O

X41

terminals

U1
V1
W1
U2
V2
W2

UDC+

UDC-

U1 V1

W1 X41 U2 V2 W2

Power

cable
PE

terminals

PE

Frame size R5 without front and connection box

Frame size R6 without front and connection box covers

covers

Location of the line-side converter

Location of the motor-side converter

RMIO board
RMIO board

The ACS800-31/U31

 25

Terms

Line-side converter: A converter that is connected to the supply network and is

capable of transferring energy from the network to the DC link.

Motor-side converter: A converter that is connected to the motor and controls the

motor operation.

Operation principle

The line-side and motor-side converters consist of six insulated gate bipolar

transistors (IGBT) with free wheeling diodes.

The converters have their own control programs. The parameters of both programs

can be viewed and changed using one control panel. The control panel can be

switched between the converters as described on page 86.

Line-side converter

The IGBT supply module rectifies three phase AC current to direct current for the

intermediate DC link of the drive. The intermediate DC link is further supplying the

motor-side converter that runs the motor. The line filter suppresses the AC voltage

and current harmonics.

By default, the converter controls the DC link voltage to the peak value of the line-to-

line voltage. The DC voltage reference can be set also higher by a parameter. The

control of the IGBT power semiconductors is based on the Direct Torque Control

(DTC) method also used in the motor control of the drive. Two line currents and the

DC link voltage are measured and used for the control.

Motor-side converter

The motor control is based on the Direct Torque Control (DTC) method. Two phase

currents and DC link voltage are measured and used for the control. The third phase

current is measured for earth fault protection.

The ACS800-31/U31

26

AC voltage and current waveforms

The AC line current of the drive is sinusoidal with power factor equal to 1. The IGBT

supply unit does not generate characteristic current or voltage overtones like a

traditional 6- or 12-pulse bridge does.

The Total Harmonic Distortion (THD) in current is given in chapter Technical data /

Input power connection. The THD in voltage depends slightly on the Short Circuit

Ratio in the Point of Common Coupling (PCC). The high frequency switching and

high du/dt slightly distort the voltage waveform at the input of the converter.

Typical line current (i) and voltage (u) waveforms are shown below.

u (V)

t (ms)

i (A)

t (ms)

Example spectra of the current and voltage distortion at the output of the transformer

are shown below. Each harmonic is presented as compared to fundamental voltage

(reference value = 1). n denotes the ordinal number of the harmonic.

Test 13
Test 13

Phase current (A)

Line-to-line voltage (%)
1.6
1.6

1.4
1.4

1.2
1.2

1.0
1.0

0.8
IL1 [A]
0.8
UL12 [%]

0.6
0.6

0.4
0.4

0.2
0.2

0.0
0.0

n
n

17

47
20

23

35

50
29

38
32
26

44
14
11

41
17

29

38

47
20

23

35

50
26

32
14

44
11

41

The ACS800-31/U31

 27

Printed circuit boards

The drive contains the following printed circuit boards as standard:

• main circuit board (GINT)

• motor control and I/O board (RMIO), 2 pcs

• EMC filter unit (GRFCU) when EMC equipment is selected

• filter boards (GRFC or RRFC)

• varistor board (GVAR)

• control panel (CDP 312R)

• current measurement board (GCUR, in frame size R5 only)

• charging diode board (GDIO).

DDCS communication modules

The drive includes an RDCO-03 module in the line-side converter and another

RDCO module in the motor-side converter.

The ACS800-31/U31

 28

External

control via

analogue/

digital

inputs and

outputs

The ACS800-31/U31

X39
X39
Optional module 1:

RMBA, RAIO, RDIO,

RMIO board of
RMIO board of

RDNA, RLON, RIBA,

the line-side
the motor-side

RPBA, RCAN, RCNA,

converter
converter

ID number 1
RMBP, RETA, RRIA

ID number 2

Input
=
~
Output

power
power
Application
or RTAC

=
Line-side

~
specific program
Optional module 2: RTAC,

converter

and motor
RAIO, RRIA or RDIO

control program

UDC+ UDC-
control program
DDCS communication

DDCS
module: RDCO-03 (default),

Simplified main circuit

RDCO-03
CH1
RDCO-01 or RDCO-02

CH0

Main circuit and control interfaces diagram

Optional

EMC

filter
LCL filter

U1
U2

K1
V2

V1
M

W2
3~

W1

Line-side converter
Motor-side converter

Varistor

connection

UDC+
UDC-

 29

Fieldbus control of the line-side converter

Fieldbus control of the line-side converter can only be performed via the motor-side

converter RMIO board. The control signal dataset receive and actual signal dataset

transmit addresses are shown in section Control block diagram below.

Control block diagram

The figure below shows the parameters for DC and reactive power reference

selection of the line-side converter control program. The AMC table contains actual

values and parameters of the line-side converter. The control and actual signal

interchange between the line-side and motor-side converters is also shown.

11.02 Q REF SELECT

Motor-side
Line-side converter
PARAM 24.01

converter RMIO
RMIO board

112.04 SUPPLY CTRL

98.02 COMM. MODULE
AI1

MODE = LINE CONV

= INVERTER

24.03 Q POWER REF2 SEL

AI2
24.01

Dataset 121 (CH1)

AI3

Dataset 121 (CH0)

Q POWER REF

MCW
MCW (fixed)
PERCENT

kVAr
+
PARAM 24.02

95.06 LCU Q POW REF

Q-REF(fixed)
24.02
+

PHI

95.07 LCU DC REF (V)

DC REF(fixed)
COSPHI

Dataset 122 (CH1)

Dataset 122 (CH0)

MSW
MSW (fixed)

24.04

9.12 LCU ACT SIGNAL 1

106 (value)

9.13 LCU ACT SIGNAL 2

110 (value)

11.01 DC REF SELECT

Dataset 123 (CH1)

Dataset 123 (CH0)
PARAM 23.01

95.08 LCU PAR1 SEL

106

95.09 LCU PAR2 SEL

DC VOLT REF

110
AMC
AI1

table AI2
23.01

AI3

FIELD BUS

MCW = Main Control Word

MSW = Main Status Word

The ACS800-31/U31

30

Connection diagram of the RMIO board in the line-side converter

Internal connections to the RMIO board for the ACS800 IGBT Supply Control

Program are shown below. Do not change the connections.

X20

Terminal block size:

1 VREF- Reference voltage -10 VDC,

cables 0.3 to 3.3 mm

(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-
R
= 100 ohm

in

7 AI3+ By default, not in use. 0(4)...20 mA,

8 AI3-
Rin

= 100 ohm

9 AO1+ By default, not in use. 0(4)...20 mA,

10 AO1-
R

L < 700 ohm

11 AO2+ By default, not in use. 0(4)...20 mA,

12 AO2-
RL < 700 ohm

1)

non-programmable I/O
X22

1 1)

DI1 Acknowledgement of converter fan

2)

External earth (ground) fault

2 DI2 By default not in use.

indication via digital input DI4: See

3 DI3 Acknowledgement from main contactor
1)

parameter 30.04 EXT EARTH FAULT.

2)

4 DI4 By default not in use.

5 3)

3)

External alarm/fault indication via

DI5 By default not in use.

digital input DI5: See parameter 30.05

6 DI6 By default not in use.

EXT EVENT. 7 +24V +24 VDC max. 100 mA

8 +24V

9 DGND Digital ground

10 DGND Digital ground

11 DI7(DIIL) Stop/Start

X23

1 +24V Auxiliary voltage output or input, non-

2 GND
isolated, 24 VDC 250 mA

X25

1 RO11 Relay output 1: By default not in

2 RO12
use.

3 RO13

X26

1 RO21 Relay output 2: By default not in

2 RO22
use.

3 RO23

X27

1 RO31 Relay output 3: Main contactor

1)

control

2 RO32

3 RO33

+ 24 VDC

The ACS800-31/U31

 31

Type code

The type code contains information on the specifications and configuration of the

drive. The first digits from left express the basic configuration (e.g. ACS800-31-

0030-5). The optional selections are given thereafter, separated by plus signs (e.g.

+E202). The main selections are described below. Not all selections are available for

all types. For more information, refer to ACS800 Ordering Information (EN code:

64556568, available on request).

Selection Alternatives

Product series ACS800 product series

Type 31 wall mounted. When no options are selected: IP21, Control Panel

CDP312R, DDCS communication option module RDCO-03, no EMC

filter, Standard Application Program, cable connection box (cabling from

below), boards with coating, one set of manuals.

U31 wall mounted (USA). When no options are selected: UL type 1, Control

Panel CDP312R, DDCS communication option module RDCO-03, no

EMC filter, US version of the Standard Application Program (three-wire

start/stop as default setting), US gland/conduit plate, boards with coating,

one set of English manuals.

Size Refer to Technical data: IEC data or NEMA data.

Voltage range
2 208/220/230/240 VAC

(nominal rating in bold)

3 380/400/415 VAC

5 380/400/415/440/460/480/500 VAC

7 525/575/600/690 VAC

+ options

Degree of protection B051 IP20 (UL type open)

Filter E200 EMC/RFI filter for second environment TN (grounded) system,

unrestricted distribution, drive category C3

E202 EMC/RFI filter for first environment TN (grounded) system, restricted

distribution, drive category C2

Cabling H357 European lead-through plate for the ACS800-U31

H358 US/UK gland/conduit plate for the ACS800-31

Control panel 0J400 no control panel

Fieldbus K... Refer to ACS800 Ordering Information (EN code: 64556568).

I/O L...

Application program N...

Manual language R...

Safety features Q950 Prevention of Unexpected Start

The ACS800-31/U31

32

The ACS800-31/U31

 33

Mechanical installation

Unpacking the unit

The drive is delivered in a box that also contains:

• plastic bag containing: screws (M3), clamps and cable lugs (2 mm

, M3) for

grounding the control cable screens

• residual voltage warning stickers

• hardware manual

• appropriate firmware manuals and guides

• optional module manuals

• delivery documents.

Delivery check

Check that there are no signs of damage. Before attempting installation and

operation, check the information on the type designation label of the drive to verify

that the unit is of the correct type. The label includes an IEC and NEMA rating, C-UL,

CSA and CE markings, a type code and a serial number, which allow individual

recognition of each unit. The first digit of the serial number refers to the

manufacturing plant. The next four digits refer to the unit’s manufacturing year and

week, respectively. The remaining digits complete the serial number so that there

are no two units with the same serial number.

Mechanical installation

34

The type designation label is attached to the heat sink and the serial number label to

the lower part of the back plate of the unit. Example labels are shown below.

Type designation label

Serial number label

Moving the unit

Lift the unit using the lifting holes at the top and bottom.

Lifting a unit of frame size R6

Mechanical installation

 35

Before installation

The drive must be installed in an upright position with the cooling section facing a

wall. Check the installation site according to the requirements below. Refer to

chapter Dimensional drawings for frame details.

Requirements for the installation site

See chapter Technical data for the allowed operation conditions of the drive.

Wall

The wall should be as close to vertical as possible, of non-flammable material and

strong enough to carry the weight of the unit. Check that there is nothing on the wall

to inhibit the installation.

Floor

The floor/material below the installation should be non-flammable.

Free space around the unit

Required free space around the drive to enable cooling air flow, service and

maintenance is shown below in millimetres and [inches].

200 [7.9]

50 [2.0]
50 [2.0]

200 [7.9]

IP21 (UL 1)
Cooling air flow

Mechanical installation

36

Mounting the drive on the wall

Units without vibration dampers

1. Mark the locations for the four holes. The mounting points are shown in chapter

Dimensional drawings.

2. Fix the screws or bolts to the marked locations.

3. Position the drive onto the screws on the wall. Note: Lift the drive by its lifting

holes, not by its cover.

4. Tighten the screws in the wall securely.

Units with vibration dampers

In applications with considerable vibration in the frequency range of 50 Hz to

100 Hz, vibration dampers can be used. For units of frame size R5, see ACS800-01/

U1 Vibration Damper Installation Guide [3AFE68295351 (English)]. For units of

frame size R6, contact ABB for installation instructions.

Cabinet installation

The drive can be installed in a cabinet without the plastic front, top and connection

box covers and without the lead-through plate. Vibration dampers are not needed.

The required distance between parallel units is 50 millimetres (1.97 in.) in

installations without the front cover. The cooling air entering the unit must not exceed

+40°C (+104°F). Contact ABB, if two units are to be installed side by side at a

distance smaller than 50 millimetres (1.97 in.), i.e. the side air holes will be covered

at one side.

Mechanical installation

 37

Preventing cooling air recirculation

Prevent air recirculation inside and outside the cabinet.

Example

HOT

AREA

Main air flow out

Air baffle plates

COOL
AREA

Main air flow in

Mechanical installation

38

Unit above another

Lead the out-coming hot cooling air away from the air input of the drive above.

Example

max.+40°C (+104°F)

Mechanical installation

 39

Planning the electrical installation

What this chapter contains

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.

To which products this chapter applies

This chapter applies to the ACS800-01/U1, ACS800-11/U11, ACS800-31/U31,

ACS800-02/U2, ACS800-04/U4, and ACS800-07/U7 types up to -0610-x.

Note: All options described in this chapter are not available for all products. Check

the availability from section Type code on page 31.

Motor selection and compatibility

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 · U

N of the drive

• motor nominal current is 1/6 ... 2 · I

2hd of the drive in DTC control and

0 ... 2 · I

2hd in scalar control. The control mode is selected by a drive parameter.

Planning the electrical installation

40

3. Check that the motor voltage rating meets the application requirements:

If the drive is equipped

… and … … then the motor voltage

with …
rating should be …

diode supply
no resistor braking is in use U

ACS800-01, -U1, -02, -U2,

frequent or long term brake cycles will
U

ACeq1

-04, -04M, -U4 -07, -U7

be used

IGBT supply
DC link voltage will not be increased
U

ACS800-11, -U11, -31, -

from nominal (parameter setting)

U31, -17, -37

DC link voltage will be increased from
U

ACeq2

nominal (parameter setting)

N
= Rated input voltage of the drive

ACeq1
= U

DC/1.35

ACeq2
= U

DC/1.41

ACeq
is the equivalent AC power source voltage of the drive in VAC.

DC
is the maximum DC link voltage of the drive in VDC.

For resistor braking: U

DC= 1.21 × nominal DC link voltage.

For units with IGBT supply: See the parameter value.

(Note: Nominal DC link voltage is U

N × 1.35 or U

N × 1.41 in VDC.)

See notes 6 and 7 below the Requirements table, pages 43 and 44.

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 1: When the supply voltage is 440 V and a drive with a diode supply is

operating in 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.

Example 2: When the supply voltage is 440 V and the drive is equipped with an

IGBT supply, the maximum peak voltage in the motor terminals can be

approximated as follows: 440 V · 1.41 · 2 = 1241 V. Check that the motor

insulation system withstands this voltage.

Planning the electrical installation

 41

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 generate 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 the hardware 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:

• optional du/dt filter (protects motor insulation system and reduces bearing

currents).

• common mode filter (mainly reduces bearing currents).

Planning the electrical installation

42

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 motor life or damage the motor bearings.

Motor type Nominal mains

Requirement for

voltage (AC line

Motor insulation

Manufacturer

ABB du/dt filter, insulated N-end bearing and ABB common mode

voltage)

system
filter

N < 100 kW

P
100 kW < P

N < 350 kW
N > 350 kW

and
or
or

frame size < IEC 315

frame size > IEC 315
frame size > IEC 400

PN < 134 HP
134 HP < P

N < 469 HP
PN > 469 HP

and frame size <

or frame size >
or frame size >

NEMA500
NEMA500
NEMA580

A
Random-
U

N < 500 V Standard - +N + N + CMF

B
wound M2_
500 V < U

N < 600 V Standard + du/dt + du/dt + N + du/dt + N + CMF

B
and M3_

or

Reinforced - +N + N + CMF

600 V < U

N < 690 V Reinforced + du/dt + du/dt + N + du/dt + N + CMF

Form-wound
380 V < U

N < 690 V Standard n.a. + N + CMF P

N < 500 kW: + N +

HX_ and AM_

CMF

N > 500 kW: + N +

CMF + du/dt

Old* form-
380 V < U

N < 690 V Check with the

+ du/dt with voltages over 500 V + N + CMF

wound HX_
motor

and modular
manufacturer.

Random-
0 V < U

N < 500 V Enamelled wire

+ N + CMF

wound HX_
with fibre glass

500 V < U

N < 690 V taping

+ du/dt + N + CMF

and AM_ **

N
Random-
U

N < 420 V Standard: Û

=
-
LL
+ N or CMF + N + CMF

O
wound and
1300 V

N
form-wound
420 V < U

N < 500 V Standard: Û

=
+ du/dt
LL
+ du/dt + N + du/dt + N + CMF

-
1300 V

or

+ du/dt + CMF

or

Reinforced: Û
=
-
LL
+ N or CMF + N + CMF

1600 V, 0.2

microsecond rise

time

500 V < U

N < 600 V Reinforced: Û

LL =
+ du/dt + du/dt + N + du/dt + N + CMF

1600 V
or

+ du/dt + CMF

or

Reinforced: Û
=
-
LL
+ N or CMF + N + CMF

1800 V

600 V < U

N < 690 V Reinforced: Û

=
+ du/dt
LL
+ du/dt + N + du/dt + N + CMF

1800 V

Reinforced: Û
=
-
LL
N + CMF N + CMF
2000 V, 0.3

microsecond rise

time ***

Planning the electrical installation

 43

* 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 is 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.

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

Abbreviation Definition

N
nominal voltage of the supply network

LL
peak line-to-line voltage at motor terminals which the motor insulation must withstand

N
motor nominal power

du/dt du/dt filter at the output of the drive +E205

CMF common mode filter +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 < P

N < 350 kW to motors with P
N < 100 kW. Apply the requirements of range P
N >

350 kW to motors within the range 100 kW < P

N < 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 < P

N < 200 kW PN > 200 kW

N < 74 HP
P
N < 268 HP
74 HP < P
N > 268 HP

A
Random-
U

N < 500 V Standard - +N + N + CMF

B
wound M3AA,
500 V < U
< 600 V Standard + du/dt + du/dt + N + du/dt + N + CMF

N
B
M3AP, M3BP

or

Reinforced - +N + N + CMF

600 V < U

N < 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 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.

Planning the electrical installation

44

Note 7: Drives with an IGBT supply unit

If voltage is raised by the drive (this is a parameter selectable function), select the motor insulation

system according to the increased intermediate circuit DC voltage level, especially in the 500 V supply

voltage range.

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 · Û

LL/(du/dt). Read Û
LL and du/dt from the diagrams below. Multiply

the values of the graph by the supply voltage (U

N). In case of drives with an IGBT supply unit or resistor

braking, the Û
LL and du/dt values are approximately 20 % higher.

3.0
5.5
Û

LL/U

N
5.0

2.5
du/dt

------------- (1/µs)

4.5
U
N

2.0
4.0

3.5

1.5

3.0

LL/U

1.0
2.5

du/dt

------------- (1/µs)

U
N

2.0

0.5

1.5

0.0
1.0

100 200 300

100 200 300

Cable length (m)

Cable length (m)

With du/dt Filter

Without du/dt Filter

Note 9: Sine filters protect the motor insulation system. Therefore, du/dt filter can be replaced with a

sine filter. The peak phase-to-phase voltage with the sine filter is approximately 1.5 × U
N.

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 the permanent magnet

synchronous motor and the drive output. The switch is needed to isolate the motor

during any maintenance work on the drive.

Planning the electrical installation

 45

Supply connection

Disconnecting device (disconnecting means)

ACS800-01, ACS800-U1, ACS800-11, ACS800-U11, ACS800-31, ACS800-U31,

ACS800-02 and ACS800-U2 without enclosure extension, ACS800-04, ACS800-U4

Install a hand-operated input disconnecting device (disconnecting means) between

the AC power source and the drive. The disconnecting device must be of a type that

can be locked to the open position for installation and maintenance work.

ACS800-02 and ACS800-U2 with enclosure extension, ACS800-07 and ACS800-U7

These units are equipped with a hand-operated input disconnecting device

(disconnecting means) which isolates the drive and the motor from the AC power as

standard. The disconnecting device does not, however, isolate the input busbars

from the AC power. Therefore, during installation and maintenance work on the

drive, the input cables and busbars must be isolated from the input power with a

disconnector at the distribution board or at the supplying transformer.

EU

To meet the European Union Directives, according to standard EN 60204-1, Safety

of Machinery, the disconnecting device must be one of the following types:

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

• disconnector that has an auxiliary contact that in all cases causes switching

devices to break the load circuit before the opening of the main contacts of the

disconnector (EN 60947-3)

• circuit breaker suitable for isolation in accordance with EN 60947-2.

US

The disconnecting means must conform to the applicable safety regulations.

Fuses

See section Thermal overload and short-circuit protection.

Planning the electrical installation

46

Thermal overload and short-circuit protection

Thermal overload protection

The drive protects itself and the input and motor cables against thermal overload

when the cables are dimensioned according to the nominal current of the drive. No

additional thermal protection devices are needed.

WARNING! If the drive is connected to multiple motors, a separate thermal overload

switch or a circuit breaker must be used for protecting each cable and motor. These

devices may require a separate fuse to cut off the short-circuit current.

The drive protects the motor cable and motor in a short-circuit situation when the

motor cable is dimensioned according to the nominal current of the drive.

Planning the electrical installation

 47

Short-circuit protection

Protect the input cable and drive against short-circuit according to the following

guide lines.

Circuit diagram Drive type Short-circuit

protection

DRIVE IS NOT EQUIPPED WITH INPUT FUSES

ACS800-01
Protect the drive and

Distribution
Drive or drive
ACS800-U1
input cable with fuses

board
Input cable
module
or a circuit breaker.

ACS800-02

See footnotes 1) and

1)
ACS800-U2+0C111
2).

~
M

~
3~
ACS800-11

ACS800-U11

ACS800-31

ACS800-U31

I >

2)
ACS800-04

~
M

~
3~
ACS800-U4

DRIVE IS EQUIPPED WITH INPUT FUSES

ACS800-02+C111
Protect the input cable

Distribution
ACS800-U2
with fuses or a circuit

board
Input cable
Drive
breaker according to

ACS800-07

local regulations. See

3)
4)

~
M
ACS800-U7
footnotes 3) and 4).

~
3~

Drive

4)

~
M

I>

~
3~

1) Size the fuses according to local safety regulations, appropriate input voltage and the rated current of

the drive (see Technical data).

Standard gG fuses (US: CC or T for the ACS800-U1, ACS800-U11 and ACS800-U31; T or L for the

ACS800-U2 and ACS800-U4) will protect the input cable in short-circuit situations, restrict drive

damage and prevent damage to adjoining equipment in case of a short-circuit inside the drive.

Check that the operating time of the fuse is below 0.5 seconds (0.1 seconds with ACS800-11/

U11, ACS800-31/U31). The operating time depends on the fuse type (gG or aR), supply network

impedance and the cross-sectional area, material and length of the supply cable. In case the 0.5

seconds (0.1 seconds with ACS800-11/U11 and ACS800-31/U31) operating time is exceeded with gG

fuses (US: CC/T/L), ultrarapid (aR) fuses will in most cases reduce the operating time to an acceptable

level. The US fuses must be of the “non-time delay” type.

For fuse ratings, see Technical data.

Planning the electrical installation

48

2) Circuit breakers which have been tested by ABB with the ACS800 can be used. Fuses must be used

with other circuit breakers. Contact your local ABB representative for approved breaker types and

supply network characteristics.

The protective characteristics of circuit breakers depend on the type, construction and settings of the

breakers. There are also limitations pertaining to the short-circuit capacity of the supply network.

WARNING! Due to the inherent operating principle and construction of circuit breakers,

independent of the manufacturer, hot ionized gases may escape from the breaker

enclosure in case of a short-circuit. To ensure safe use, special attention must be paid to

the installation and placement of the breakers. Follow the manufacturer’s instructions.

Note: Circuit breakers without fuses are not recommended in the USA.

3) Size the fuses according to local safety regulations, appropriate input voltage and the rated current of

the drive (see Technical data).

4) ACS800-07/U7 units and ACS800-02/U2 units with enclosure extension are equipped with standard gG

(US: T/L) or optional aR fuses listed in Technical data. The fuses restrict drive damage and prevent

damage to adjoining equipment in case of a short-circuit inside the drive.

Check that the operating time of the fuse is below 0.5 seconds. The operating time depends on the

fuse type (gG or aR), supply network impedance and the cross-sectional area, material and length of

the supply cable. In case the 0.5 seconds operating time is exceeded with gG fuses (US: CC/T/L),

ultrarapid (aR) fuses will in most cases reduce the operating time to an acceptable level. The US fuses

must be of the “non-time delay” type.

For fuse ratings, see Technical data.

Planning the electrical installation

 49

Ground fault protection

The drive is equipped with an internal ground fault protective function to protect the

unit against ground faults in the motor and motor cable. This is not a personal safety

or a fire protection feature. The ground fault protective function can be disabled with

a parameter, refer to the appropriate ACS800 Firmware Manual.

The EMC filter of the drive includes capacitors connected between the main circuit

and the frame. These capacitors and long motor cables increase the ground leakage

current and may cause fault current circuit breakers to function.

Emergency stop devices

For safety reasons, install the emergency stop devices at each operator control

station and at other operating stations where emergency stop may be needed.

Note: Pressing the stop key ( ) on the control panel of the drive does not generate

an emergency stop of the motor or separate the drive from dangerous potential.

ACS800-02/U2 with enclosure extension and ACS800-07/U7

An emergency stop function is optionally available for stopping and switching off the

whole drive. Two stop categories according to IEC/EN 60204-1 (1997) are available:

immediate removal of power (Category 0 for ACS800-02/U2 and ACS800-07/U7)

and controlled emergency stop (Category 1 for ACS800-07/U7).

Restarting after an emergency stop

After an emergency stop, the emergency stop button must be released and the drive

started by turning the operating switch of the drive from position “ON” to “START”.

Planning the electrical installation

50

Prevention of Unexpected Start

The ACS800-04, ACS800-31/U31 and ACS800-07/U7 can be equipped with an

optional Prevention of Unexpected Start function according to standards IEC/

EN 60204-1: 1997; ISO/DIS 14118: 2000 and EN 1037: 1996.

The Prevention of Unexpected Start function disables the control voltage of the

power semiconductors, thus preventing the inverter from generating the AC voltage

required to rotate the motor. By using this function, short-time operations (like

cleaning) and/or maintenance work on non-electrical parts of the machinery can be

performed without switching off the AC power supply to the drive.

The operator activates the Prevention of Unexpected Start function by opening a

switch on a control desk. An indicating lamp on the control desk will light, signalling

that the prevention is active. The switch can be locked out.

The user must install on a control desk near the machinery:

• switching/disconnecting device for the circuitry. “Means shall be provided to

prevent inadvertent, and/or mistaken closure of the disconnecting device.”

EN 60204-1: 1997.

• indicating lamp; on = starting the drive is prevented, off = drive is operative.

For connections to the drive, see the circuit diagram delivered with the drive.

WARNING! The Prevention of Unexpected Start function does not disconnect the

voltage of the main and auxiliary circuits from the drive. Therefore maintenance work

on electrical parts of the drive or the motor can only be carried out after isolating the

drive system from the main supply.

Note: The Prevention of Unexpected Start function is not intended for stopping the

drive. If a running drive is stopped by using the Prevention of Unexpected Start

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

stop.

Planning the electrical installation

 51

Selecting the power cables

General rules

Dimension the mains (input power) and motor cables according to local

regulations:

• The cable must be able to carry the drive load current. See chapter Technical

data for the rated currents.

• The cable must be rated for at least 70 °C maximum permissible temperature of

conductor in continuous use. For US, see Additional US requirements.

• The inductance and impedance of the PE conductor/cable (grounding wire) must

be rated according to permissible touch voltage appearing under fault conditions

(so that the fault point voltage will not rise excessively when a ground fault

occurs).

• 600 VAC cable is accepted for up to 500 VAC. 750 VAC cable is accepted for up

to 600 VAC. For 690 VAC rated equipment, the rated voltage between the

conductors of the cable should be at least 1 kV.

For drive frame size R5 and larger, or motors larger than 30 kW (40 HP),

symmetrical shielded motor cable must be used (figure below). A four-conductor

system can be used up to frame size R4 with up to 30 kW (40 HP) motors, but

shielded symmetrical motor cable is recommended.

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

2
2

S (mm
)
Sp (mm
)

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.

The motor cable and its PE pigtail (twisted shield) should be kept as short as

possible in order to reduce electromagnetic emission.

Planning the electrical installation

52

Alternative power cable types

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

Recommended

Symmetrical shielded cable: three phase conductors

Aseparate 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 mm

[motors > 30 kW (40 HP)].

Motor cable shield

To effectively suppress radiated and conducted radio-frequency emissions, the

shield conductivity must be at least 1/10 of the phase conductor conductivity. The

requirements are easily met with a copper or aluminium shield. The minimum

requirement of the motor cable shield of the drive is shown below. It consists of a

concentric layer of copper wires with an open helix of copper tape. The better and

tighter the shield, the lower the emission level and bearing currents.

Copper wire screen

Helix of copper tape
Inner insulation
Insulation jacket

Cable core

Planning the electrical installation

 53

Additional US requirements

Type MC continuous corrugated aluminum armor cable with symmetrical grounds or

shielded power cable must be used for the motor cables if metallic conduit is not

used. For the North American market, 600 VAC cable is accepted for up to 500 VAC.

1000 VAC cable is required above 500 VAC (below 600 VAC). For drives rated over

100 amperes, the power cables must be rated for 75 °C (167 °F).

Conduit

Where conduits must be coupled together, bridge the joint with a ground conductor

bonded to the conduit on each side of the joint. Bond the conduits also to the drive

enclosure. Use separate conduits for input power, motor, brake resistor, and control

wiring. When conduit is employed, type MC continuous corrugated aluminium armor

cable or shielded cable is not required. A dedicated ground cable is always required.

Note: Do not run motor wiring from more than one drive in the same conduit.

Armored cable /shielded power cable

Six conductor (3 phases and 3 ground) type MC continuous corrugated aluminum

armor cable with symmetrical grounds is available from the following suppliers (trade

names in parentheses):

• Anixter Wire & Cable (Philsheath)

• BICC General Corp (Philsheath)

• Rockbestos Co. (Gardex)

• Oaknite (CLX).

Shielded power cables are available from Belden, LAPPKABEL (ÖLFLEX) and

Pirelli.

Power factor compensation capacitors

Power factor compensation is not needed with AC drives. However, if a drive is to be

connected in a system with compensation capacitors 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.

Planning the electrical installation

54

If there are power factor compensation capacitors in parallel with the three phase

input of the drive:

1. 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.

2. 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.

3. Check that the power factor compensation unit is suitable for use in systems with

AC drives i.e. 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 cable, or connect the shields of the

cables otherwise together.

• US: Install the equipment in a metal enclosure in a way that the conduit or motor

cable shielding runs consistently without breaks from the drive to the motor.

Bypass connection

WARNING! Never connect the supply power to the drive output terminals U2, V2

and W2. If frequent bypassing is required, employ mechanically connected switches

or contactors. Mains (line) voltage applied to the output can result in permanent

damage to the unit.

Before opening a contactor (DTC control mode selected)

Stop the drive and wait for the motor to stop before opening a contactor between the

output of the drive and the motor when the DTC control mode is selected. See the

appropriate ACS800 application program firmware manual for the required

parameter settings. Otherwise, the contactor will be damaged. In scalar control, the

contactor can be opened with the drive running.

Planning the electrical installation

 55

Protecting the relay output contacts and attenuating disturbances in case

of inductive loads

Inductive loads (relays, contactors, motors) cause voltage transients when switched

off.

The relay contacts on the RMIO board are protected with varistors (250 V) against

overvoltage peaks. In spite of this, it is highly recommended to equip inductive loads

with noise attenuating circuits [varistors, RC filters (AC) or diodes (DC)] in order to

minimize the EMC emission at switch-off. If not suppressed, the disturbances may

connect capacitively or inductively to other conductors in the control cable and form

a risk of malfunction in other parts of the system.

Install the protective component as close to the inductive load as possible. Do not

install protective components at the RMIO board terminal block.

RMIO

Relay outputs

Varistor
X25

1 RO1

2 RO1

230 VAC

3 RO1

RC filter X26

1 RO2

2 RO2

230 VAC

3 RO2

Diode
X27

1 RO3

2 RO3

24 VDC

3 RO3

Planning the electrical installation

56

Selecting the control cables

All control cables must be shielded.

Use a double-shielded twisted pair cable (Figure a, e.g. JAMAK by NK Cables,

Finland) for analogue signals. This type of cable is recommended for the pulse

encoder signals also. Employ one individually shielded pair for each signal. Do not

use common return for different analogue signals.

A double-shielded cable is the best alternative for low-voltage digital signals but

single-shielded twisted pair cable (Figure b) is also usable.

a
b

Adouble-shielded twisted
A 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 (e.g. ÖLFLEX by LAPPKABEL,

Germany) has been tested and approved by ABB.

Control panel cable

In remote use, the cable connecting the control panel to the drive must not exceed 3

metres (10 ft). The cable type tested and approved by ABB is used in control panel

option kits.

Planning the electrical installation

 57

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

ACS800 Firmware Manual.

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).

Routing the cables

Route the motor cable away from other cable routes. Motor cables of several drives

can be run in parallel installed next to each other. It is recommended that the motor

cable, input power cable and control cables be installed on separate trays. Avoid

long parallel runs of motor cables with other cables in order to decrease

electromagnetic interference caused by the rapid changes in the drive output

voltage.

Where control cables must cross power cables make sure they are arranged at an

angle as near to 90 degrees as possible. Do not run extra cables through the drive.

The cable trays must have good electrical bonding to each other and to the

grounding electrodes. Aluminium tray systems can be used to improve local

equalizing of potential.

Planning the electrical installation

58

A diagram of the cable routing is shown 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

230 V
230 V

24 V
(120 V)
24 V
(120 V)

Not allowed unless the 24 V cable is

Lead 24 V and 230 V (120 V) control

insulated for 230 V (120 V) or insulated

cables in separate ducts inside the

with an insulation sleeving for 230 V

cabinet.

(120 V).

Planning the electrical installation

 59

Electrical installation

What this chapter contains

This chapter describes the electrical installation procedure of the drive.

WARNING! The work described in this chapter may only be carried out by a qualified

electrician. Follow the Safety instructions on the first pages of this manual. Ignoring

the safety instructions can cause injury or death.

Make sure that the drive is disconnected from the mains (input power) during

the installation. If the drive is already connected to the mains, wait for 5 min

after disconnecting mains power.

Checking the insulation of the installation

Drive

Every drive has been tested for insulation between the main circuit and the chassis

(2500 V rms 50 Hz for 1 second) at the factory. Therefore, do not make any voltage

tolerance or insulation resistance tests (e.g. hi-pot or megger) on any part of the

drive.

Input cable

Check the insulation of the input cable according to local regulations before

connecting it to the drive.

Motor and motor cable

Check the insulation of the motor and motor cable as follows:

1. Check that the motor cable is disconnected from the drive output terminals U2,

V2 and W2.

M 2. Measure the insulation resistances of the motor cable and motor between each

ohm
phase and the Protective Earth by using a measuring voltage of 1 kV DC. The

PE

insulation resistance must be higher than 1 Mohm.

Electrical installation

60

IT (ungrounded) systems

In units with EMC filter options (+E202 and +E200 in the type code), disconnect the

filter capacitors before connecting the drive to an ungrounded system.

WARNING! If a drive with EMC filter selection +E202 or +E200 is installed on an IT

system [an ungrounded power system or a high resistance-grounded (over 30 ohms)

power system], the system will be connected to earth potential through the EMC

filter capacitors of the drive. This may cause danger or damage the unit.

Disconnecting the EMC filter capacitors

Remove the two screws shown below.

View of frame size R5

Note concerning units of frame size R5: When the capacitors of EMC filter +E202

or +E200 are disconnected, the EMC Directive requirements in second environment

will not be fulfilled.

Note concerning units of frame size R6: When the capacitors of EMC filter +E202

are disconnected, the EMC Directive requirements may not be fulfilled in first

environment, but are fulfilled in second environment. When the capacitors of EMC

filter +E200 are disconnected, the EMC Directive requirements in second

environment are still fulfilled.

See chapter Technical data /CE marking.

Electrical installation

 61

Connecting the power cables

Diagram

Drive

INPUT
OUTPUT

PE
U1
V1 W1
UDC+ UDC- U2
V2 W2

1)
2)

3)
4)

(PE) PE

(PE)

5)

V1
W1

U1

For alternatives, see

Planning the electrical

3 ~

installation:
Motor

Disconnecting device

(disconnecting means)
L1 L2 L3

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

If shielded cable is used (not required but

For minimum radio frequency interference:

recommended), use a separate PE cable (1) or a

• ground the cable shield 360 degrees at the lead-through of

cable with a grounding conductor (2) if the

the motor terminal box

conductivity of the input cable shield is < 50% of the

conductivity of the phase conductor.

Ground the other end of the input cable shield or PE

conductor at the distribution board.

360 degrees grounding

3) 360 degrees grounding recommended if shielded

cable is used

Conductive gaskets

4) 360 degrees grounding required

• or ground the cable by twisting the shield as follows:

flattened width > 1/5 · length.

b > 1/5 · a

5) Use a separate grounding cable if the conductivity of

the cable shield is < 50% of the conductivity of the

b

phase conductor and there is no symmetrically

constructed grounding conductor in the cable (see

Planning the electrical installation / Selecting the

power cables).

Note:

If there is a symmetrically constructed grounding

conductor in the motor cable in addition to the

conductive shield, connect the grounding conductor to

the grounding terminal at the drive and motor ends.

Do not use an asymmetrically constructed motor cable

for motors > 30 kW (40 HP). Connecting its fourth

conductor at the motor end increases bearing currents

and causes extra wear.

Electrical installation

62

Conductor stripping lengths

Strip the conductor ends as follows to fit them inside the power cable connection

terminals.

Frame size Stripping length

mm in.

R5 16 0.63

R6 28 1.10

Allowed wire sizes, tightening torques

See Technical data: Cable entries.

Wall installed units (European version)

Power cable installation procedure

1. Remove the connection box cover.

2. Remove the front cover by releasing the retaining clip with a screw driver and

lifting the cover from the bottom outwards.

3. Remove the clear plastic shroud of the phase conductor terminals.

4. Cut adequate holes into the rubber grommets and slide the grommets onto the

cables. Slide the cables through the holes of the bottom plate.

5. Strip off the outer sheathing of the cables under the 360 degrees grounding

clamps. Fasten the clamps onto the stripped parts of the cables.

6. Tighten the grounding clamps onto the twisted shields of the cables.

7. Connect the phase conductors of the mains cable to the U1, V1 and W1

terminals and the phase conductors of the motor cable to the U2, V2 and W2

terminals.

8. Cut holes to the clear plastic shroud for the conductors in frame size R5 and in

cable lug installations of frame size R6.

9. Press the clear plastic shroud onto the phase conductor terminals.

10. Secure the cables outside the unit mechanically. Connect the control cables as

described in section Connecting the control cables on page 67. Fasten the

covers, see Fastening the control cables and covers on page 70.

Electrical installation

 63

Views of frame size R5

9
9

U1
V1 W1
UDC+
UDC-
U2
V2 W2

PE
6

Electrical installation

64

Frame sizes R6: Cable lug installation [16 to 70 mm

(6 to 2/0 AWG) cables]

Remove the screw terminals. Fasten the cable lugs

to the remaining bolts with M10 nuts.

Isolate the ends of

the cable lugs with

PE

insulating tape or

shrink tubing.

Shroud on the conductor terminals (screw

terminal installation)

5
5

9
9

Frame size R6: Screw terminal installation [95 to 185 mm

(3/0 to 350 AWG)]cables

PE
6

a. Connect the cable to the terminal.

b. Connect the terminal to the drive.

WARNING! If the wire size is less than

95 mm
(3/0 AWG), a cable lug must

5
5
be used. A cable of wire size less than

95 mm
(3/0 AWG) connected to this

terminal will loosen and may damage

the drive.

Electrical installation

 65

Wall installed units (US version)

1. Remove the connection box cover.

2. Remove the front cover by releasing the retaining clip with a screw driver and

lifting the cover from the bottom outwards.

8
8

3
3

2
4
4

3. Remove the gland plate by undoing the fastening screws.

4. Make the cable entry holes in the gland plate by breaking off the suitable knock-

out plates with a screw driver.

5. Fasten the cable glands to the opened holes of the gland plate.

6. Lead the cables through the glands.

7. Fasten the gland plate (3).

8. Connect the grounding conductors of the input and motor cables to the

grounding clamps.

9. Remove the clear plastic shroud as shown in section Power cable installation

procedure on page 62.

10. Connect the phase conductors of the input cable to the U1, V1 and W1 terminals

and the phase conductors of the motor cable to the U2, V2 and W2 terminals.

See Wall installed units (European version) for cabling figures. In case of a cable

lug installation, use UL listed cable lugs and tools given below or corresponding

to meet UL requirements.

Electrical installation

66

Wire size Compression lug Crimping tool

kcmil/AWG Manufacturer Type Manufacturer Type No. of crimps

4 Burndy YA4C-L4BOX Burndy MY29-3 1

Ilsco CCL-4-38 Ilsco MT-25 1

2 Burndy YA2C-L4BOX Burndy MY29-3 2

Ilsco CRC-2 Ilsco IDT-12 1

Ilsco CCL-2-38 Ilsco MT-25 1

1 Burndy YA1C-L4BOX Burndy MY29-3 2

Ilsco CRA-1-38 Ilsco IDT-12 1

Ilsco CCL-1-38 Ilsco MT-25 1

Thomas & Betts 54148 Thomas & Betts TBM-8 3

1/0 Burndy YA25-L4BOX Burndy MY29-3 2

Ilsco CRB-0 Ilsco IDT-12 1

Ilsco CCL-1/0-38 Ilsco MT-25 1

Thomas & Betts 54109 Thomas & Betts TBM-8 3

2/0 Burndy YAL26T38 Burndy MY29-3 2

Ilsco CRA-2/0 Ilsco IDT-12 1

Ilsco CCL-2/0-38 Ilsco MT-25 1

Thomas & Betts 54110 Thomas & Betts TBM-8 3

11. Tighten the clamping nuts of the cable glands.

After connecting the control cables, fasten the clear plastic shroud and front covers.

Warning sticker

There are warning stickers in different languages inside the packing box of the drive.

Attach a warning sticker in the language of your choice onto the plastic skeleton

above the power cable terminals.

Cabinet installed units (IP 00, UL type open)

The drive can be installed in a cabinet without the plastic front, top and connection

box covers and without the lead-through plate.

It is recommended:

• to ground the cable shield 360 degrees at the cabinet entry. Grounding with the

360 degrees grounding clamps at the connection box back plate is then not

needed.

• to lead the cable unstripped as close to the terminals as possible. Ground the

twisted shields of the power cables under the PE and grounding clamps.

Secure the cables mechanically.

Protect the RMIO board terminals X25 to X27 against contact when input voltage

exceeds 50 VAC.

Cover the power cable terminals with the clear plastic shroud as shown in section

Power cable installation procedure on page 62.

Electrical installation

 67

Connecting the control cables

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

Connect the control cables as described below. Connect the conductors to the

appropriate detachable terminals of the RMIO board [refer to chapter Motor control

and I/O board (RMIO)]. Tighten the screws to secure the connection.

Terminals

View of frame size R6

Control panel

Optional module 2

Optional module 1

DDCS communication module: RDCO.

Channel CH1 is used for the internal communication

between the line-side and motor-side converters.

Control cable

grounding: see
Detachable connection terminals (pull up)

section 360

degrees

grounding

Electrical installation

68

360 degrees grounding

Insulation

Double-shielded cable
Single-shielded cable

When the outer surface of the shield is covered with non-conductive material

• Strip the cable carefully (do not cut the grounding wire and the shield)

• Turn the shield inside out to expose the conductive surface.

• Wrap the grounding wire around the conductive surface.

• Slide a conductive clamp onto the conductive part.

• Fasten the clamp to the grounding plate with a screw as close as possible to the

terminals where the wires are about to be connected.

Connecting the shield wires

Single-shielded cables: Twist the grounding wires of the outer shield and connect

them through the shortest possible route to the nearest grounding hole with a cable

lug and a screw. Double-shielded cables: Connect each pair cable shield (twisted

grounding wires) with other pair cable shields of the same cable to the nearest

grounding hole with a cable lug and a screw.

Do not connect shields of different cables to the same cable lug and grounding

screw.

Leave the other end of the shield unconnected or ground it indirectly via a few

nanofarads high-frequency capacitor (e.g. 3.3 nF / 630 V). The shield can also be

grounded directly at both ends if they are in the same ground line with no significant

voltage drop between the end points.

Keep the signal wire pairs twisted as close to the terminals as possible. Twisting the

wire with its return wire reduces disturbances caused by inductive coupling.

Electrical installation

 69

Cabling of I/O and fieldbus modules

Module

As short as possible

Shield

Note: The RDIO module does not

include a terminal for cable shield

grounding. Ground the pair cable

shields here.

Pulse encoder module cabling

Note1: If the encoder is of unisolated type,

ground the encoder cable at the drive end

only. If the encoder is galvanically isolated

RTAC
from the motor shaft and the stator frame,

As short as possible ground the encoder cable shield at the drive

and the encoder end.

Note 2: Twist the pair cable wires.

Shield

Wrap copper tape around the

stripped part of the cable under the

clamp. Be careful. Do not cut the

grounding wire. Clamp as close to

the terminals as possible.

Electrical installation

70

Fastening the control cables and covers

When all control cables are connected, fasten them together with cable ties. Units

with a connection box: fasten the cables to the entry plate with cable ties. Units with

a gland box: tighten the clamping nuts of the cable glands.

Fasten the connection box cover.

Replace the front cover.

Installation of optional modules and PC

The optional module (such as fieldbus adapter, I/O extension module and the pulse

encoder interface) is inserted in the optional module slot of the RMIO board (see

Connecting the control cables) and fixed with two screws. See the appropriate

optional module manual for cable connections.

Note: Two RDCO modules are provided for the DDCS fibre optic link between the

RMIO boards of the line-side and motor-side converters. Channel CH0 of the

RDCO-03 module in the line-side converter and channel CH1 of the RDCO module

in the motor-side converter are used for the internal communication. In case multiple

devices are to be connected to one channel, they must be connected in a ring.

Electrical installation

 71

Installation of AGPS board (Prevention of

Unexpected Start, +Q950)

What this chapter contains

This chapter describes the electrical installation of the optional Prevention of

Unexpected Start function (+Q950) of the drive.

Prevention of Unexpected Start (+Q950)

The optional Prevention of Unexpected Start function includes an AGPS board which

is connected to the drive and an external power supply. See also chapter Planning

the electrical installation, page 50.

Installation of the AGPS board

WARNING! Dangerous voltages can be present on the AGPS board even when the

115...230 V supply is switched off. Follow the Safety instructions on the first pages of

this manual and the instruction in this chapter when working on the AGPS board.

Make sure that the drive is disconnected from the mains (input power) and the

115...230 V source for the AGPS board is switched off during installation and

maintenance. If the drive is already connected to the mains, wait for 5 min after

disconnecting mains power.

See

• page 24 for location of terminal block X41 of the drive

• page 73 for the circuit diagram

• page 74 for the dimensions of the AGPS board

• section AGPS-11C in chapter Technical data for the technical data of the board.

Note: Maximum cable length between AGPS terminal block X2 and the drive

terminal block is restricted to 10 metres.

Installation of AGPS board (Prevention of Unexpected Start, +Q950)

72

Connect the AGPS board as follows:

• Remove the enclosure cover by undoing the fixing screws (1).

• Ground the bottom plate of the enclosure or via terminal X1:1 of the AGPS board.

• Connect the cable delivered with the kit between terminal block X2 of the AGPS

board (2) and drive terminal block X41.

• Connect a cable between connector X1 of the AGPS board (3) and the

115...230 V source.

• Fasten the enclosure cover back with screws.

X2

X1

115...230 V
3

Installation of AGPS board (Prevention of Unexpected Start, +Q950)

 73

Circuit diagram

This circuit diagram shows how the AGPS-11 kit is installed.

Drive

115/230 VAC

3AFE00374994

Installation of AGPS board (Prevention of Unexpected Start, +Q950)

74

Dimensional drawing

The dimensional drawing of the AGPS board is shown below.

3AFE68293898

Installation of AGPS board (Prevention of Unexpected Start, +Q950)

 75

Motor control and I/O board (RMIO)

What this chapter contains

This chapter shows

• external control connections to the RMIO board for the ACS800 Standard

Application Program (Factory Macro)

• specifications of the inputs and outputs of the board.

To which products this chapter applies

This chapter applies to ACS800 units which employ RMIO-01 board from revision J

onwards and RMIO-02 board from revision H onwards.

Note for the ACS800-02 with enclosure extension and the ACS800-07

The connections for the RMIO board shown below apply also to optional terminal

block X2 available for the ACS800-02 and ACS800-07. The terminals of the RMIO

board are wired to terminal block X2 internally.

Terminals of X2 accept cables from 0.5 to 4.0 mm

2

(22 to 12 AWG). 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 screw driver with a blade thickness of 0.6 mm

(0.024 in.) and width of 3.5 mm (0.138 in.), e.g. PHOENIX CONTACT SZF 1-

0,6X3,5.

Note on terminal labelling

Optional modules (Rxxx) may have identical terminal designations with the RMIO

board.

Motor control and I/O board (RMIO)

76

Note on external power supply

External +24 V power supply for the RMIO board is recommended if

• the application requires a fast start after connecting the input power supply

• fieldbus communication is required when the input power supply is disconnected.

The RMIO board can be supplied from an external power source via terminal X23 or

X34 or via both X23 and X34. The internal power supply to terminal X34 can be left

connected when using terminal X23.

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

terminal X34, the loose end of the cable removed from the RMIO board terminal

must be secured mechanically to a location where it cannot come into contact with

electrical parts. If the screw terminal plug of the cable is removed, the wire ends

must be individually insulated.

Parameter settings

In Standard Application Program, set parameter 16.9 CTRL BOARD SUPPLY to

EXTERNAL 24V if the RMIO board is powered from an external supply.

Motor control and I/O board (RMIO)

 77

External control connections (non-US)

External control cable connections to the RMIO board for the ACS800 Standard

Application Program (Factory Macro) are shown below. For external control

connections of other application macros and programs, see the appropriate

Firmware Manual.

X2* RMIO

X20 X20

RMIO
1 1 VREF- Reference voltage -10 VDC, 1 kohm < R
<

Terminal block size:

2 2 AGND
10 kohm

cables 0.3 to 3.3 mm

(22 to 12 AWG)
X21 X21

Tightening torque:
1 1 VREF+ Reference voltage 10 VDC, 1 kohm < RL <

0.2 to 0.4 Nm
2 2 AGND
10 kohm

(0.2 to 0.3 lbf ft) 3 3 AI1+ Speed reference 0(2) ... 10 V, R

in >

4 4 AI1-
200 kohm

5 5 AI2+ By default, not in use. 0(4) ... 20 mA, Rin =

6 6 AI2-
100 ohm

7 7 AI3+ By default, not in use. 0(4) ... 20 mA, R

in =

8 8 AI3-
100 ohm

rpm
9 9 AO1+ Motor speed 0(4)...20 mA =
0...motor nom.

10 10 AO1-
speed, RL < 700 ohm

A
11 11 AO2+ Output current 0(4)...20 mA =
0...motor

12 12 AO2-
nom. current, R
L < 700 ohm

* optional terminal block in ACS800-02

X22 X22

and ACS800-07

1 1 DI1 Stop/Start

1)
1)

Only effective if par. 10.03 is set to

2 2 DI2 Forward/Reverse

REQUEST by the user.

3 3 DI3 Not in use

4 2)

4 DI4 Acceleration & deceleration select

2)

0 = open, 1 = closed
3)

5 5 DI5 Constant speed select

DI4 Ramp times according to

6 6 DI6 Constant speed select
3)

0 parameters 22.02 and 22.03

7 7 +24VD +24 VDC max. 100 mA

1 parameters 22.04 and 22.05

8 8 +24VD

3)

9 9 DGND1 Digital ground

See par. group 12 CONSTANT

SPEEDS.
10 10 DGND2 Digital ground

11 4)

DI5 DI6 Operation

11 DIIL Start interlock (0 = stop)

0 0 Set speed through AI1

X23 X23

1 0 Constant speed 1
1 1 +24V Auxiliary voltage output and input, non-

5)

0 1 Constant speed 2
2 2 GND
isolated, 24 VDC 250 mA

1 1 Constant speed 3
X25 X25

1 1 RO1 Relay output 1: ready

4)

See parameter 21.09 START INTRL

2 2 RO1

FUNC.

5)

3 3 RO1

Total maximum current shared

X26 X26

between this output and optional

modules installed on the board.

1 1 RO2 Relay output 2: running

2 2 RO2

3 3 RO2

X27 X27

1 1 RO3 Relay output 3: fault (-1)

Fault
2 2 RO3

3 3 RO3

Motor control and I/O board (RMIO)

78

External control connections (US)

External control cable connections to the RMIO board for the ACS800 Standard

Application Program (Factory Macro US version) are shown below. For external

control connections of other application macros and programs, see the appropriate

Firmware Manual.

X2* RMIO

RMIO
X20 X20

Terminal block size:

1 1 VREF- Reference voltage -10 VDC, 1 kohm < R
<

cables 0.3 to 3.3 mm

(22 to 12 AWG)
2 2 AGND
10 kohm

Tightening torque:
X21 X21

1 1 VREF+ Reference voltage 10 VDC, 1 kohm < RL <

0.2 to 0.4 Nm (0.2 to 0.3 lbf ft)

2 2 AGND
10 kohm

3 3 AI1+ Speed reference 0(2) ... 10 V, R

in >

4 4 AI1-
200 kohm

5 5 AI2+ By default, not in use. 0(4) ... 20 mA, Rin =

6 6 AI2-
100 ohm

7 7 AI3+ By default, not in use. 0(4) ... 20 mA, R

in =

8 8 AI3-
100 ohm

rpm
9 9 AO1+ Motor speed 0(4)...20 mA =
0...motor nom.

10 10 AO1-
speed, RL < 700 ohm

A
11 11 AO2+ Output current 0(4)...20 mA =
0...motor

12 12 AO2-
nom. current, R
L < 700 ohm

X22 X22

1 1 DI1 Start ( )

2 2 DI2 Stop ( )

* optional terminal block in ACS800-U2

1)

3 3 DI3 Forward/Reverse

and ACS800-U7
2)

4 4 DI4 Acceleration & deceleration select

1)
3)

Only effective if par. 10.03 is set to

5 5 DI5 Constant speed select

REQUEST by the user.

6 6 DI6 Constant speed select
3)

7 7 +24VD +24 VDC max. 100 mA

2)

0 = open, 1 = closed

8 8 +24VD

DI4 Ramp times according to

9 9 DGND1 Digital ground

0 parameters 22.02 and 22.03

10 10 DGND2 Digital ground

1 parameters 22.04 and 22.05

4)

11 11 DIIL Start interlock (0 = stop)

3)
X23 X23

See par. group 12 CONSTANT

SPEEDS.
1 1 +24V Auxiliary voltage output and input, non-

5)

DI5 DI6 Operation

2 2 GND
isolated, 24 VDC 250 mA

0 0 Set speed through AI1

X25 X25

1 0 Constant speed 1
1 1 RO1 Relay output 1: ready

0 1 Constant speed 2
2 2 RO1

1 1 Constant speed 3 3 3 RO1

X26 X26

4)

See parameter 21.09 START INTRL

1 1 RO2 Relay output 2: running

FUNC.

5)
2 2 RO2

Total maximum current shared

between this output and optional

3 3 RO2

modules installed on the board.

X27 X27

1 1 RO3 Relay output 3: fault (-1)

Fault
2 2 RO3

3 3 RO3

Motor control and I/O board (RMIO)

 79

RMIO board specifications

Analogue inputs

With Standard Application Program two programmable differential current inputs

(0 mA / 4 mA ... 20 mA, R
in = 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, R

L < 700 ohm

Resolution 0.1 % (10 bit)

Inaccuracy ± 1 % (Full Scale Range) at 25 °C (77 °F). Temperature coefficient: ± 200 ppm/°C

(± 111 ppm/°F) max.

Digital inputs

With Standard Application Program six programmable digital inputs (common ground:

24 VDC, -15 % to +20 %) and a start interlock input. Group isolated, can be divided in

two isolated groups (see Isolation and grounding diagram below).

Thermistor input: 5 mA, < 1.5 kohm “1” (normal temperature), > 4 kohm “0”

(high temperature), open circuit “0” (high temperature).

Internal supply for digital inputs (+24 VDC): short-circuit proof. An external 24 VDC

supply can be used instead of the internal supply.

Isolation test voltage 500 VAC, 1 min

Logical thresholds < 8 VDC “0”, > 12 VDC “1”

Input current DI1 to DI 5: 10 mA, DI6: 5 mA

Filtering time constant 1 ms

Motor control and I/O board (RMIO)

80

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 57.

Motor control and I/O board (RMIO)

 81

Isolation and grounding diagram

(Test voltage: 500 V AC)

X20

1 VREF-

2 AGND

X21

1 VREF+

2 AGND

3 AI1+

4 AI1-
Common mode

voltage between

5 AI2+

channels ±15 V

6 AI2-

7 AI3+

8 AI3-

9 AO1+

10 AO1-

11 AO2+

12 AO2-

X22

1 DI1

2 DI2

3 DI3

4 DI4

Jumper J1 settings:

9 DGND1

5 DI5
All digital inputs share a common

J1

6 DI6
ground. This is the default setting.

7 +24VD

8 +24VD
Grounds of input groups

11 DIIL
DI1…DI4 and DI5/DI6/DIIL

or

are separate (isolation

10 DGND2
voltage 50 V).

X23

1 +24 V

2 GND

X25

1 RO1

2 RO1

3 RO1

X26

1 RO2

2 RO2

3 RO2

X27

1 RO3

2 RO3

3 RO3

(Test voltage:

4 kV AC)
Ground

Motor control and I/O board (RMIO)

82

Motor control and I/O board (RMIO)

 83

Installation checklist

What this chapter contains

This chapter contains an installation checklist.

Installation checklist

Check the mechanical and electrical installation of the drive before start-up. Go

through the checklist below together with another person.

WARNING! Only qualified electricians are allowed to commission the drive. Read

and follow the Safety instructions on the first pages of this manual. Ignoring the

safety instructions can cause injury or death.

Check...

MECHANICAL INSTALLATION

The ambient operating conditions are allowed. (See Mechanical installation, Technical data)

The unit is fixed properly on a vertical non-flammable wall. (See Mechanical installation.)

The cooling air will flow freely.

The motor and the driven equipment are ready for start. (See Planning the electrical

installation: Motor selection and compatibility, Technical data: Motor connection.)

ELECTRICAL INSTALLATION (See Planning the electrical installation, Electrical installation.)

The +E202 and +E200 EMC filter capacitors are disconnected if the drive is connected to an

IT (ungrounded) system.

The capacitors are reformed if stored over one year (refer to ACS 600/800 Capacitor

Reforming Guide [64059629 (English)].

The drive is grounded properly.

The mains (input power) voltage matches the drive nominal input voltage.

The mains (input power) connections at U1, V1 and W1 and their tightening torques are OK.

Appropriate mains (input power) fuses and disconnector are installed.

Installation checklist

84

Check...
The motor connections at U2, V2 and W2 and their tightening torques are OK.

The motor cable is routed away from other cables.

There are no power factor compensation capacitors in the motor cable.

The external control connections inside the drive are OK.

There are no tools, foreign objects or dust from drilling inside the drive.

Mains (input power) voltage cannot be applied to the output of the drive (with bypass

connection).

Drive, motor connection box and other covers are in place.

Installation checklist

 85

Start-up and use

What this chapter contains

This chapter describes the start-up procedure and use of the drive.

Start-up and use

WARNING! Only qualified electricians are allowed to commission the drive. Read

and follow the Safety instructions on the first pages of this manual. Ignoring the

safety instructions can cause injury or death.

Perform the start-up procedure as described in the appropriate application program

firmware manual. The parameters of the line-side converter control program

need not be set in a normal start-up procedure or in normal use. However, it is

recommended to set parameter 16.15 I/O START MODE to DI2 LEVEL:

• if the motor is started and stopped frequently. This prolongs the lifespan of the

charging contactor.

• when starting the motor without start delay is required.

• if the drive is connected to other drives via a common DC bus. Otherwise, the

charging resistor may be damaged.

For setting of parameter 16.15 I/O START MODE, change the control panel to

control the line-side converter as shown on page 86.

Note

• In normal use, have the control panel control the RMIO board of the motor-side

converter (default, ID number 1). If the control panel is set to control the RMIO

board of the line-side converter (ID number 2), the drive does not stop by

pressing the control panel Stop key.

• Do not change the ID numbers of the converters from the default settings. If the

ID numbers of the line-side and motor side converters are set equal, the control

panel stops communicating.

• Keep parameter 20.05 OVERVOLTAGE CTRL set to ON (default) when no brake

chopper and resistor are installed. The parameter index is valid for Standard

Application Program. For other application programs, see the appropriate

firmware manual. For parameter settings with a brake chopper and resistor, see

chapter Resistor braking.

Start-up and use

86

Control panel

The drive is equipped with a control panel (type CDP-312R). The CDP-312R is the

user interface of the line-side converter and the motor-side converter of the drive,

providing the essential controls such as Start/Stop/Direction/Reset/Reference, and

the parameter settings for the units’ application programs. More information on using

the panel can be found in the Firmware Manual delivered with the drive.

The control panel is wired to both the line-side converter and the motor-side

converter using a Y-splitter. The converter that is currently being controlled is

indicated by the converter name on the drive display; the suffix “MR” denotes motor-

side converter, “LR” denotes line-side converter. The control is switched between the

converters as follows:

To control the line-side converter...

Step Action Press key Display (example)

1. Enter the Drive Selection Mode.

Note: In local control mode, the motor-side converter trips

ACS 800 0050_5MR

if parameter 30.02 PANEL LOSS is set to FAULT. Refer to

DRIVE

ASXR7xxx

the appropriate application program firmware manual.

ID-NUMBER 1

2. Scroll to ID number 2.

ACS 800 0050_5LR

IXXR7xxx

ID-NUMBER 2

3. Verify the change to the line-side converter and display the

warning or fault text .

2 -> 380. 0 V

ACT
ACS 800 0050_5LR

** FAULT **
DC OVERVOLT ( 3210)

WARNING! The drive does not stop by pressing the control panel Stop key in local

control mode.

Start-up and use

 87

To control the motor-side converter...

Step Action Press key Display (example)

1. Enter the Drive Selection Mode.

ACS 800 0050_5LR

DRIVE

IXXR7xxx

ID-NUMBER 2

2. Scroll to ID number 1.

ACS 800 0050_5MR

ACXR7xxx

ID-NUMBER 1

3. Verify the change to the motor-side converter.

1 L -> 0. 0 rpm I
ACT
FREQ 0. 00 Hz

CURRENT 0. 00 A

POWER 0. 00 %

Start-up and use

88

Start-up and use

 89

Actual signals and parameters

What this chapter contains

This chapter contains listings of parameters specific to the ACS800-31 and ACS800-

U31.

Line-side converter actual signals and parameters in the motor-side

converter application program

This section describes the actual signals and parameters of the line-side converter

control program which are copied to the motor-side converter application program.

The user can view two actual signals (by default, measured line current and

intermediate circuit DC voltage) and change the values of the copied parameters

without changing the control panel between two control boards and programs. In

normal use, there is no need to set these or other parameters of the line-side

converter control program. For more information on the parameters, refer to IGBT

Supply Control Program Firmware Manual [3AFE68315735 (English)], available on

request from ABB.

Terms and abbreviations

Term Definition

Actual signal Signal measured or calculated by the drive. Can be monitored by the

user. No user setting possible.

Def. Default value

FbEq Fieldbus equivalent: The scaling between the value shown on the control

panel and the integer used in serial communication.

Parameter A user-adjustable operation instruction of the drive.

Actual signals

No. Name/Value Description FbEq Def.

09 ACTUAL SIGNALS
Signals from the line converter.

09.12 LCU ACT SIGNAL 1 Line converter signal selected by par. 95.08 LCU PAR1 SEL. 1=1 106

09.13 LCU ACT SIGNAL 2 Line converter signal selected by par. 95.09 LCU PAR2 SEL. 1=1 110

Actual signals and parameters

90

Parameters

No. Name/Value Description FbEq Def.

95 HARDWARE SPECIF
Line converter references and actual signal selections.

95.06 LCU Q POW REF Reactive power reference for the line converter i.e. the value for
0

par. 24.02 Q POWER REF2 in the IGBT Supply Control Program.

Scaling example 1: 10000 equals to a value of 10000 of parameter

24.02 Q POWER REF2 and 100% of par. 24.01 Q POWER REF

(i.e. 100% of the converter nominal power given in par. 04.06

CONV NOM POWER) when par. 24.03 Q POWER REF2 SEL is

set to PERCENT.

Scaling example 2: Par. 24.03 Q POWER REF2 SEL is set to kVAr.

A value of 1000 of par. 95.06 equals to 1000 kVAr of par. 24.02 Q

POWER REF2. Value of par. 24.01 Q POWER REF is then 100 ·

(1000 kVAr divided by converter nominal power in kVAr)%.

Scaling example 3: Par. 24.03 Q POWER REF2 SEL is set to PHI.

A value of 10000 of par. 95.06 equals to a value of 100 deg of

parameter 24.02 Q POWER REF2 which is limited to 30 deg. The

value of par. 24.01 Q POWER REF will be determined

approximately according to the following equation where P is read

from actual signal 1.06 POWER:

P
P
Q

30
=
---

cos
=
------------------------

S
2
2
30 deg

P
+
Q

Positive reference 30 deg denotes capacitive load.

Negative reference 30 deg denotes inductive load.

Par. 24.02 -30

-10
0
10
30 (deg)

Par. 95.06

-10000 -3000
-1000
0
1000
3000
+10000

-10000 ... +10000 Setting range. 1 = 1

95.07 LCU DC REF (V) DC voltage reference for line converter i.e. the value for par. 23.01
0

DC VOLT REF.

0 … 1100 Setting range in volts. 1 = 1 V

95.08 LCU PAR1 SEL Selects the line-side converter address from which actual signal
106

09.12 LCU ACT SIGNAL 1 is read.

0 … 10000 Parameter index. 1 = 1

95.09 LCU PAR2 SEL Selects the line-side converter address from which actual signal
110

09.13 LCU ACT SIGNAL 2 is read.

0 … 10000 Parameter index. 1 = 1

Actual signals and parameters

 91

ACS800-31/U31 specific parameters in the IGBT Supply Control Program

The signals and parameters of the IGBT Supply Control Program which are specific

to the ACS800-31 and ACS800-U31 are described in the tables below. These

parameters need not be set in a normal start-up. For more information on

parameters of the IGBT Supply Control Program, refer to IGBT Supply Control

Program Firmware Manual [3AFE68315735 (English)].

Terms and abbreviations

Term Definition

B Boolean data type

C Character string data type

Def. Default value data type

FbEq Fieldbus equivalent: the scaling between the value shown on the control

panel and the integer used in serial communication

I Integer data type

R Real data type

T. Data type (see B, C, I, R)

Parameters

No. Name/Value Description T./FbEq Def.

16 SYSTEM CTR
Parameter lock, parameter back-up etc.

INPUTS

16.15 I/O START MODE Selects I/O control start mode when par. 98.01 COMMAND SEL is set
B DI2 EDGE

to I/O.

DI2 EDGE Starts the line converter by digital input DI2 rising edge. The line
0

converter starts to modulate and the charging resistors will be by-

passed when the motor-side converter is started.

DI2 LEVEL Starts the line converter by the level of digital input DI2. The line
1
converter starts to modulate and the charging resistors will be by-

passed when the line converter RMIO board is powered, its digital

input DI2 is ON and there are no faults.

Note: This selection changes the value of par. 98.01 COMMAND SEL

from the default setting MCW to I/O on the next RMIO board power-

up.

Actual signals and parameters

 92

No. Name/Value Description T./FbEq Def.

31 AUTOMATIC RESET
Automatic fault reset.

Automatic resets are possible only for certain fault types and when the

automatic reset function is activated for that fault type.

The automatic reset function is not operational if the drive is in local

control (L visible on the first row of the control panel display).

WARNING! If the start command is selected and it is ON, the

line converter may restart immediately after automatic fault

reset. Ensure that the use of this feature will not cause

danger.

WARNING! Do not use these parameters when the drive is

connected to a common DC bus. The charging resistors may

be damaged in an automatic reset.

31.01 NUMBER OF TRIALS Defines the number of automatic fault resets the drive performs within
I 0

the time defined by parameter 31.02 TRIAL TIME.

0…5 Number of the automatic resets 0

31.02 TRIAL TIME Defines the time for the automatic fault reset function. See parameter
R 30 s

31.01 NUMBER OF TRIALS.

1.0 … 180.0 s Allowed resetting time 100 …

18000

31.03 DELAY TIME Defines the time that the drive will wait after a fault before attempting
R 0 s

an automatic reset. See parameter 31.01 NUMBER OF TRIALS.

0.0 … 3.0 s Resetting delay 0 … 300

31.04 OVERCURRENT Activates/deactivates the automatic reset for the line converter
B NO

overcurrent fault.

NO Inactive 0

YES Active 65535

31.05 OVERVOLTAGE Activates/deactivates the automatic reset for the intermediate link
B NO

overvoltage fault.

NO Inactive 0

YES Active 65535

31.06 UNDERVOLTAGE Activates/deactivates the automatic reset for the intermediate link
B NO

undervoltage fault.

NO Inactive 0

YES Active 65535

Actual signals and parameters

 93

Fixed parameters with the ACS800-31 and ACS800-U31

When the IGBT Supply Control Program is loaded into the ACS800-31 or ACS800-

U31, the following parameters are set to the default values given in the table below.

Parameter Default value If changed,

11.01 DC REF SELECT FIELDBUS the default values will be

11.02 Q REF SELECT PARAM 24.02

restored on the next power-

up.

98.01 COMMAND SEL MCW. Note: If par. 16.15 I/O

START MODE is set to DI2 LEVEL,

the default value is changed to I/O

on the next RMIO board power-up.

98.02 COMM. MODULE INVERTER

30.02 EARTH FAULT FAULT.

the default values will not

Note: The ACS800-31/U31 line

be restored on the next

converter is not equipped with

power-up. Do not change.

internal earth fault supervision.

If the default values are

changed, the drive will not

70.01 CH0 NODE ADDR 120

operate.

70.19 CH0 HW CONNECTION RING

70.20 CH3 HW CONNECTION RING

71.01 CH0 DRIVEBUS MODE NO

Actual signals and parameters

94

Actual signals and parameters

 95

Maintenance

What this chapter contains

This chapter contains preventive maintenance instructions.

Safety

WARNING! Read the Safety instructions on the first pages of this manual before

performing any maintenance on the equipment. Ignoring the safety instructions can

cause injury or death.

Maintenance intervals

If installed in an appropriate environment, the drive requires very little maintenance.

This table lists the routine maintenance intervals recommended by ABB.

Maintenance Interval Instruction

Capacitor reforming Every year when stored See Reforming.

Heatsink temperature check

Depends on the dustiness of
See Heatsink.

and cleaning
the environment (every 6 to 12

months)

Change of additional cooling

Every three years See Additional fan.

fan

Main cooling fan change Every six years See Main cooling fan.

Capacitor change Every ten years See Capacitors.

Maintenance

96

Heatsink

The heatsink fins pick up dust from the cooling air. The drive runs into

overtemperature warnings and faults if the heatsink is not clean. In a “normal”

environment (not dusty, not clean) the heatsink should be checked annually, in a

dusty environment more often.

Clean the heatsink as follows (when necessary):

1. Remove the cooling fan (see section Main cooling fan).

2. Blow clean compressed air (not humid) from bottom to top and simultaneously

use a vacuum cleaner at the air outlet to trap the dust. Note: If there is a risk of

the dust entering adjoining equipment, perform the cleaning in another room.

3. Replace the cooling fan.

Main cooling fan

The cooling fan lifespan of the drive is about 50 000 operating hours. The actual

lifespan depends on the drive usage and ambient temperature. See the appropriate

ACS800 firmware manual for an actual signal which indicates the hours of usage of

the fan. For resetting the running time signal after a fan replacement, please contact

ABB.

Fan failure can be predicted by the increasing noise from fan bearings and the

gradual rise in the heatsink temperature in spite of heatsink cleaning. If the drive is

operated in a critical part of a process, fan replacement is recommended once these

symptoms start appearing. Replacement fans are available from ABB. Do not use

other than ABB specified spare parts.

Maintenance

 97

Fan replacement (R5, R6)

1. Loosen the fastening screws of the top plate.

2. Push the top plate backwards.

3. Lift the top plate up.

4. Disconnect the fan supply wires (detachable connector).

5. Lift the fan up.

6. Install the new fan in reverse order.

1
1

5
4

Additional fan

Replacement (R5)

Remove the front cover. The fan is located on the right-hand side of the control panel

(R5). Lift the fan out and disconnect the cable. Install the new fan in reverse order.

Maintenance

98

Replacement (R6)

Remove the top cover by lifting it by the rear edge. To remove the fan, release the

retaining clips by pulling the back edge (1) of the fan upwards. Disconnect the cable

(2, detachable terminal). Install the new fan in reverse order.

View from above when top

cover is removed

Air flow upwards

1
2

Rotation

direction

Capacitors

The drive intermediate circuit employs several electrolytic capacitors. Their lifespan

is from 45 000 to 90 000 hours depending on drive loading and ambient

temperature. Capacitor life can be prolonged by lowering the ambient temperature.

It is not possible to predict a capacitor failure. Capacitor failure is usually followed by

a mains fuse failure or a fault trip. Contact ABB if capacitor failure is suspected.

Replacements are available from ABB. Do not use other than ABB specified spare

parts.

Reforming

Reform (re-age) spare part capacitors once a year according to ACS 600/800

Capacitor Reforming Guide (code: 3AFE64059629).

LEDs

This table describes LEDs of the drive.

Where LED When the LED is lit

RMIO board * Red Drive in fault state

Green The power supply on the board is OK.

Control panel mounting platform Red Drive in fault state

Green The main +24 V power supply for the control panel and the

RMIO board is OK.

* The LEDs are not visible

Maintenance

 99

Fault tracing

What this chapter contains

This chapter describes the fault tracing of the line-side converter. For motor-side

converter fault tracing, see the appropriate application program firmware manual.

Faults and warnings displayed by the CDP-312R Control Panel

The control panel will display the warnings and faults of the unit (i.e. line-side

converter or motor-side converter) the panel is currently controlling.

Information on warnings and faults concerning the line-side converter are contained

within the IGBT Supply Control Program Firmware Manual [3AFE68315735

(English)].

The warnings and faults concerning the motor-side converter are dealt with in the

application program (e.g. Standard Application Program) Firmware Manual.

Warning/Fault message from unit not being monitored by control panel

Flashing messages WARNING, ID:2 or FAULT, ID:2 on the control panel display

indicate a warning or fault state in the line-side converter when the panel is

controlling the motor-side converter:

FAULT, ID: 2

ACS 800 0490_3MR

*** FAULT ***

LINE CONV ( FF51)

To display the warning or fault identification text, switch the control panel to view the

line-side converter as described in section Control panel on page 86.

Conflicting ID numbers

If the ID numbers of the line-side and the motor-side converters are set equal, the

control panel stops functioning. To clear the situation:

• Disconnect the panel cable from the RMIO board of the motor-side converter.

• Set the ID number of the line-side converter RMIO board to 2. For the setting

procedure, see the application program (e.g. Standard Application Program)

Firmware Manual.

• Connect the disconnected cable to the RMIO board of the motor-side converter

again and set the ID number to 1.

Fault tracing

100

Fault tracing

 101

Technical data

What this chapter contains

This chapter contains the technical specifications of the drive, e.g. the ratings, sizes

and technical requirements, provisions for fulfilling the requirements for CE and

other markings and warranty policy.

Technical data

102

IEC data

Ratings

The IEC ratings for the ACS800-31 with 50 Hz and 60 Hz supplies are given below.

The symbols are described below the table.

ACS800-31 size Nominal

No-
Light-overload
Heavy-duty use Frame
Air flow Heat

overload

ratings
use

use
size
dissipation

cont.max
I

max
P
cont.max
I

2N
P

N
I

2hd
P

hd

A
A

kW

A
kW
A
kW 3

m
/h W

Three-phase supply voltage 208 V, 220 V, 230 V or 240 V

-0011-2 34 52 7.5 32 7.5 26 5.5 R5 350 505

-0016-2 47 68 11 45 11 38 7.5 R5 350 694

-0020-2 59 90 15 56 15 45 11 R5 350 910

-0025-2 75 118 22 69 18.5 59 15 R5 350 1099

-0030-2 88 144 22 83 22 72 18.5 R5 350 1315

-0040-2 120 168 37 114 30 84 22 R6 405 1585

-0050-2 150 234 45 143 45 117 30 R6 405 2125

-0060-2 169 264 45 157 45 132 37 R6 405 2530

Three-phase supply voltage 380 V, 400 V or 415 V

-0016-3 34 52 15 32 15 26 11 R5 350 550

-0020-3 38 61 18.5 36 18.5 34 15 R5 350 655

-0025-3 47 68 22 45 22 38 18.5 R5 350 760

-0030-3 59 90 30 56 30 45 22 R5 350 1000

-0040-3 72 118 37 69 37 59 30 R5 350 1210

-0050-3 86 144 45 83 45 65 30 R5 350 1450

-0060-3 120 168 55 114 55 88 45 R6 405 1750

-0070-3 150 234 75 143 75 117 55 R6 405 2350

-0100-3 165 264 90 157 75 132 75 R6 405 2800

Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V

-0020-5 31 52 18.5 29 18.5 25 15 R5 350 655

-0025-5 36 61 22 34 22 30 18.5 R5 350 760

-0030-5 47 68 30 45 30 37 22 R5 350 1000

-0040-5 58 90 37 55 37 47 30 R5 350 1210

-0050-5 70 118 45 67 45 57 37 R5 350 1450

-0060-5 82 144 55 78 45 62 37 R5 350 1750

-0070-5 120 168 75 114 75 88 55 R6 405 2350

-0100-5 139 234 90 132 90 114 75 R6 405 2800

-0120-5 156 264 110 148 90 125 75 R6 405 3400

Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V

-0060-7 57 86 55 54 45 43 37 R6 405 1750

-0070-7 79 120 75 75 55 60 55 R6 405 2350

-0100-7 93 142 90 88 75 71 55 R6 405 2800

PDM code: 00184674-G

Technical data

 103

Symbols

Nominal ratings

Icont.max
continuous rms output current. No overload capability at 40°C.

max
maximum output current. Available for 10 s at start, otherwise as long as allowed by drive

temperature.

Typical ratings:

No-overload use

Pcont.max
typical motor power. The power ratings apply to most IEC 34 motors at the nominal voltage,

230 V, 400 V, 500 V or 690 V.

Light-overload use (10% overload capability)

2N
continuous rms current. 10% overload is allowed for one minute every 5 minutes.

P
N
typical motor power. The power ratings apply to most IEC 34 motors at the nominal voltage,

230 V, 400 V, 500 V or 690 V.

Heavy-duty use (50% overload capability)

I2hd
continuous rms current. 50% overload is allowed for one minute every 5 minutes.

P
hd
typical motor power. The power ratings apply to most IEC 34 motors at the nominal voltage,

230 V, 400 V, 500 V or 690 V.

Sizing

The current ratings are the same regardless of the supply voltage within one voltage range. To achieve

the rated motor power given in the table, the rated current of the drive must be higher than or equal to

the rated motor current.

Note 1: The maximum allowed momentary motor shaft power is limited to approximately 1.3 · P
cont.max.

If the limit is exceeded, motor torque and current are automatically restricted. The function protects the

input bridge and LCL filter of the drive against overload.

Note 2: The ratings apply at an ambient temperature of 40°C (104°F). At lower temperatures the

ratings are higher (except I

max).

Note 3: Use the DriveSize PC tool for a more accurate dimensioning if the ambient temperature is

below 40°C (104°F) or the drive is loaded cyclically.

Derating

The load capacity (current and power) decreases if the installation site altitude exceeds 1000 metres

(3300 ft), or if the ambient temperature exceeds 40°C (104°F).

Temperature derating

In the temperature range +40°C (+104°F) to +50°C (+122°F) the rated output current is decreased 1%

for every additional 1°C (1.8°F). The output current is calculated by multiplying the current given in the

rating table by the derating factor.

Example If the ambient temperature is 50°C (+122°F), the derating factor is 100% - 1 %
· 10°C =

90 % or 0.90. The output current is then 0.90 · I

or 0.90 · I
.
°C
2N 2hd
Altitude derating

In altitudes from 1000 to 4000 m (3300 to 13123 ft) above sea level, the derating is 1% for every 100 m

(328 ft). For a more accurate derating, use the DriveSize PC tool.

Technical data

104

Mains cable fuses

Fuses for short-circuit protection of the mains cable are listed below. The fuses also

protect the adjoining equipment of the drive in case of a short-circuit. Check that the

operating time of the fuse is below 0.1 seconds. The operating time depends on

the supply network impedance and the cross-sectional area and length of the supply

cable. See also Planning the electrical installation: Thermal overload and short-

circuit protection. For UL recognized fuses, see NEMA data.

Note 1: In multicable installations, install only one fuse per phase (not one fuse per conductor).

Note 2: Larger fuses must not be used.

Note 3: Fuses from other manufacturers can be used if they meet the ratings.

ACS800-31 size Input

Fuse

current
A A
2

s* V Manufacturer Type IEC size

Three-phase supply voltage 208 V, 220 V, 230 V or 240 V

-0011-2 32 40 9140 500 ABB Control OFAF000H40 000

-0016-2 44 50 15400 500 ABB Control OFAF000H50 000

-0020-2 55 63 21300 500 ABB Control OFAF000H63 000

-0025-2 70 80 34500 500 ABB Control OFAF000H80 000

-0030-2 82 100 63600 500 ABB Control OFAF000H100 000

-0040-2 112 125 103000 500 ABB Control OFAF00H125 00

-0050-2 140 160 200000 500 ABB Control OFAF00H160 00

-0060-2 157 200 350000 500 ABB Control OFAF1H200 1

Three-phase supply voltage 380 V, 400 V or 415 V

-0016-3 32 40 9140 500 ABB Control OFAF000H40 000

-0020-3 35 40 9140 500 ABB Control OFAF000H40 000

-0025-3 44 50 15400 500 ABB Control OFAF000H50 000

-0030-3 55 63 21300 500 ABB Control OFAF000H63 000

-0040-3 67 80 34500 500 ABB Control OFAF000H80 000

-0050-3 80 100 63600 500 ABB Control OFAF000H100 000

-0060-3 112 125 103000 500 ABB Control OFAF00H125 00

-0070-3 140 160 200000 500 ABB Control OFAF00H160 00

-0100-3 153 200 350000 500 ABB Control OFAF1H200 1

Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V

-0020-5 29 40 9140 500 ABB Control OFAF000H40 000

-0025-5 33 40 9140 500 ABB Control OFAF000H40 000

-0030-5 44 50 15400 500 ABB Control OFAF000H50 000

-0040-5 54 63 21300 500 ABB Control OFAF000H63 000

-0050-5 65 80 34500 500 ABB Control OFAF000H80 000

-0060-5 76 100 63600 500 ABB Control OFAF000H100 000

-0070-5 112 125 103000 500 ABB Control OFAF00H125 00

-0100-5 129 160 200000 500 ABB Control OFAF00H160 00

-0120-5 145 200 350000 500 ABB Control OFAF1H200 1

Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V

-0060-7 53 63 28600 690 ABB Control OFAA0GG63 0

-0070-7 73 80 52200 690 ABB Control OFAA0GG80 0

-0100-7 86 100 93000 690 ABB Control OFAA1GG100 1

PDM code: 00184674-G

2

* maximum total I
t value for 550 V

Technical data

 105

Cable types

The table below gives copper and aluminium cable types for different load currents.

Cable sizing is based on max. 9 cables laid on a cable ladder side by side, ambient

temperature 30°C, PVC insulation, surface temperature 70°C (EN 60204-1 and

IEC 60364-5-2/2001). For other conditions, size the cables according to local safety

regulations, appropriate input voltage and the load current of the drive.

Copper cables with concentric

Aluminium cables with concentric

copper shield
copper shield

Max. load
Cable type
Max. load
Cable type

current
current

A
2

mm
A
2

mm

34 3x6 61 3x25

47 3x10 75 3x35

62 3x16 91 3x50

79 3x25 117 3x70

98 3x35 143 3x95

119 3x50 165 3x120

153 3x70 191 3x150

186 3x95

215 3x120

249 3x150

284 3x185

PDM code: 00096931-C

Cable entries

Mains, DC link and motor cable terminal sizes (per phase), accepted cable

diameters and tightening torques are given below.

Frame size U1, V1, W1, U2, V2, W2, UDC+,UDC- Earthing PE

Wire size Max. cable Ø

Tightening
Wire size Tightening

IP21
torque
torque

2
2

mm
mm Nm mm
Nm

R5 6…70 35 10 6…70 15

R6 95...185 * 53 20…40 16...95 8

* with cable lugs 16...70 mm

, tightening torque 20...40 Nm

Dimensions, weights and noise

Frame size IP21 Noise

Height Width Depth Weight

mm mm mm kg dB

R5 816 265 390 65 70

R6 970 300 439 100 73

Technical data

106

NEMA data

Ratings

The NEMA ratings for the ACS800-U31 and ACS800-31 with 60 Hz supplies are

given below. The symbols are described below the table. For sizing, derating and

50 Hz supplies, see IEC data on page 102.

max
Normal use
ACS800-U31 size
I
Heavy-duty use Frame
Air flow Heat

ACS800-31 size
size
dissipation

2N
P

N
I

2hd
P

hd

A
A
HP
A
HP 3

ft
/min BTU/Hr

Three-phase supply voltage 208 V, 220 V, 230 V or 240 V

-0011-2 52 32 10 26 7.5 R5 206 1730

-0016-2 68 45 15 38 10 R5 206 2380

-0020-2 90 56 20 45 10 R5 206 3110

-0025-2 118 69 25 59 15 R5 206 3760

-0030-2 144 83 30 72 20 R5 206 4500

-0040-2 168 114 40 84 25 R6 238 5420

-0050-2 234 143 50 117 30 R6 238 7260

-0060-2 264 157 60 132 40 R6 238 8650

Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V or 480 V

-0020-5 52 29 20 25 15 R5 206 2240

-0025-5 61 34 25 30 20 R5 206 2600

-0030-5 68 45 30 37 25 R5 206 3420

-0040-5 90 55 40 47 30 R5 206 4140

-0050-5 118 67 50 57 40 R5 206 4960

-0060-5 144 78 60 65** 50 R5 206 5980

-0070-5 168 114 75 88 60 R6 238 8030

-0100-5 234 132 100 114 75 R6 238 9570

-0120-5 264 156* 125 125 100 R6 238 11620

Three-phase supply voltage 525 V, 575 V, 600 V

-0060-7 62 54 40 43 30 R6 238 5980

-0070-7 79 75 50 60 40 R6 238 8030

-0100-7 99 88 75 71 50 R6 238 9570

PDM code: 00184674-G

allowed with motor power < 125 HP and a reactive power reference of 0

**

allowed with motor power < 50 HP and a reactive power reference of 0

Symbols

Nominal ratings

max
maximum output current. Available for 10 s at start, otherwise as long as allowed by drive

temperature.

Normal use (10% overload capability)

2N
continuous rms current. 10% overload is typically allowed for one minute every 5 minutes.

PN
typical motor power. The power ratings apply to most 4-pole NEMA rated motors (230 V,

460 Vor 575 V).

Heavy-duty use (50% overload capability)

2hd
continuous rms current. 50% overload is typically allowed for one minute every 5 minutes.

P
hd
typical motor power. The power ratings apply to most 4-pole NEMA rated motors (230 V,

460 Vor 575 V).

Note 1: The ratings apply at an ambient temperature of 40°C (104°F). At lower temperatures the

ratings are higher (except Imax).

Technical data

 107

Input cable fuses

The ratings of UL listed fuses for branch circuit protection are listed below. The fuses

also prevent damage to the adjoining equipment of the drive in case of a short-circuit

inside the drive. Check that the operating time of the fuse is below 0.1 seconds.

The operating time depends on the supply network impedance and the cross-

sectional area and length of the supply cable. The fuses must be of the “non-time

delay” type. See also Planning the electrical installation: Thermal overload and

short-circuit protection.

Note 1: In multicable installations, install only one fuse per phase (not one fuse per conductor).

Note 2: Larger fuses must not be used.

Note 3: Fuses from other manufacturers can be used if they meet the ratings.

ACS800-U31 type
Input
Fuse

ACS800-31 type
current

A A V Manufacturer Type UL class

Three-phase supply voltage 208 V, 220 V, 230 V or 240 V

-0011-2 32 40 600 Bussmann JJS-40 T

-0016-2 44 70 600 Bussmann JJS-70 T

-0020-2 55 80 600 Bussmann JJS-80 T

-0025-2 70 90 600 Bussmann JJS-90 T

-0030-2 82 100 600 Bussmann JJS-100 T

-0040-2 112 150 600 Bussmann JJS-150 T

-0050-2 140 200 600 Bussmann JJS-200 T

-0060-2 157 200 600 Bussmann JJS-200 T

Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V

-0020-5 29 40 600 Bussmann JJS-40 T

-0025-5 33 50 600 Bussmann JJS-50 T

-0030-5 44 70 600 Bussmann JJS-70 T

-0040-5 54 80 600 Bussmann JJS-80 T

-0050-5 65 90 600 Bussmann JJS-90 T

-0060-5 76 100 600 Bussmann JJS-100 T

-0070-5 112 150 600 Bussmann JJS-150 T

-0100-5 129 200 600 Bussmann JJS-200 T

-0120-5 145 200 600 Bussmann JJS-200 T

Three-phase supply voltage 525 V, 575 V, 600 V

-0060-7 53 80 600 Bussmann JJS-80 T

-0070-7 73 100 600 Bussmann JJS-100 T

-0100-7 86 125 600 Bussmann JJS-125 T

PDM code: 00184674-G

Technical data

108

Cable types

Cable sizing is based on NEC Table 310-16 for copper wires, 75°C (167°F) wire insulation at 40°C

(104°F) ambient temperature. Not more than three current-carrying conductors in raceway or cable or

earth (directly buried). For other conditions, dimension the cables according to local safety regulations,

appropriate input voltage and the load current of the drive.

Copper cables with concentric copper shield

Max. load
Cable type

current

A
AWG/kcmil

31 10

44 8

57 6

75 4

88 3

101 2

114 1

132 1/0

154 2/0

176 3/0

202 4/0

224 250 MCM or 2 x 1

251 300 MCM or 2 x 1/0

273 350 MCM or 2 x 2/0

PDM code: 00096931-C

Cable Entries

Input, DC link and motor cable (per phase) terminal sizes, accepted cable diameters

and tightening torques are given below.

Frame size U1, V1, W1, U2, V2, W2, UDC+, UDC- Grounding PE

Wire size Wire Ø

Tightening
Wire size Tightening

(UL type 1)
torque
torque

AWG in. lbf ft AWG lbf ft

R5 10...2/0 1.39 11.1 10...2/0 11.1

R6 3/0 ... 350 MCM * 2.09 14.8...29.5 5...4/0 5.9

* with cable lugs 6...2/0 AWG, tightening torque 14.8...29.5 lbf ft

Dimensions, weights and noise

Frame size UL type 1 Noise

Height Width Depth Weight

in. in. in. lb dB

R5 32.03 10.43 15.35 143 70

R6 38.19 11.81 17.28 220 73

Technical data

 109

Input power connection

Voltage (U

1) 208/220/230/240 VAC 3-phase ± 10% for 230 VAC units

380/400/415 VAC 3-phase ± 10% for 400 VAC units

380/400/415/440/460/480/500 VAC 3-phase ± 10% for 500 VAC units

525/550/575/600/660/690 VAC 3-phase ± 10% for 690 VAC units

Prospective short-circuit
Maximum allowed prospective short-circuit current in the supply is 65 kA in a second

current (IEC 60439-1,

providing that the mains cable of the drive is protected with appropriate fuses.

UL 508C)
US and Canada: The drive is suitable for use on a circuit capable of delivering not more

than 65 kA rms symmetrical amperes at the drive nominal voltage when protected by T

class fuses.

Frequency 48 to 63 Hz, maximum rate of change 17%/s

Imbalance Max. ± 3% of nominal phase to phase input voltage

Voltage dips Max. 25%

Fundamental power factor

1.00 (fundamental at nominal load)

(cos phi1 )

Harmonic distortion Harmonics are below the limits defined in IEEE519 for all Isc/IL. Each individual harmonic

current fulfils IEEE519 table 10-3 for I

L > 20. Current THD and each individual current

sc/I

harmonic fulfil IEC 61000-3-4 table 5.2 for R

sce > 66. The values will be met if the supply

network voltage is not distorted by other loads.

Rsc
THD voltage (%) THD current (%)

20 4 4

100 0.8 5

50
I

⎛ --------------------
n

THD
= ∑

⎝ I
1 contmax

THD = Total Harmonic Distortion (THD). The voltage THD depends on the short-circuit

ratio (Rsc). The spectrum of the distortion also contains interharmonics.

I
th

n = n
harmonic component

sc = R

sce = I

sc/I

Isc = short-circuit current at point of common coupling (PCC)

1contmax = continuous maximum input current of the IGBT supply unit

L = maximum demand load current

Technical data

110

Motor connection

Voltage (U

2) 0 to U

1 , 3-phase symmetrical, U

max at the field weakening point

Frequency DTC mode: 0 to 3.2 · f

fwp. Maximum frequency 300 Hz.

Nmains

fwp =
· f

Nmotor
U

Nmotor

fwp: frequency at field weakening point; U

Nmains: mains (input power) voltage;

U
Nmotor: rated motor voltage; f
Nmotor: rated motor frequency

Frequency resolution 0.01 Hz

Current See section IEC data or NEMA data.

Power limit Approximately 1.3 · P

cont.max

Field weakening point 8 to 300 Hz

Switching frequency 3 kHz (average).

Maximum recommended
300 m (984 ft). Additional restriction for units with EMC filtering (type code selections

motor cable length

+E202 and +E200): max. motor cable length is 100 m (328 ft). With longer cables the EMC

Directive requirements may not be fulfilled.

Efficiency

Approximately 97% at nominal power level

Cooling

Method Internal fan, flow direction from bottom to top.

Free space around the unit See chapter Mechanical installation.

Degrees of protection

IP20 (UL type open) and IP21 (UL type 1). IPXXD from above.

Without front cover, the unit must be protected against contact according to IP2x [see

chapter Electrical installation: Cabinet installed units (IP 00, UL type open)].

AGPS-11C

Nominal input voltage 115...230 VAC ±10%

Nominal input current 0.1 A (230 V) / 0.2 A (115 V)

Nominal frequency 50/60 Hz

Max. external fuse 16 A

X1 terminal sizes 3 x 2.5 mm

Output voltage 15 VDC ±0.5 V

Nominal output current 0.4 A

X2 terminal block type JST B4P-VH

Ambient temperature 0...50°C

Relative humidity Max. 90%, no condensation allowed

Dimensions (with enclosure) 167 x 128 x 52 mm (Height x Weight x Depth)

Weight (with enclosure) 0.75 kg

Approvals C-UL, US listed

Technical data

 111

Ambient conditions

Environmental limits for the drive are given below. The drive is to be used in a heated,

indoor, controlled environment.

Operation
Storage
Transportation

installed for stationary use

in the protective package
in the protective package

Installation site altitude 0 to 4000 m (13123 ft) above

- -

sea level [above 1000 m

(3281 ft), see section

Derating]

Air temperature -15 to +50°C (5 to 122°F).

No
-40 to +70°C (-40 to +158°F) -40 to +70°C (-40 to +158°F)

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.

Contamination levels
No conductive dust allowed.

(IEC 60721-3-3, IEC 60721-3-

Boards with coating:
Boards with coating:
Boards with coating:

2, IEC 60721-3-1)
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),

2
2
2
2
2
2

max. 7 m/s
(23 ft/s
)
max. 7 m/s
(23 ft/s
)
max. 15 m/s
(49 ft/s
)

(13.2 to 100 Hz) sinusoidal

(13.2 to 100 Hz) sinusoidal
(9 to 200 Hz) sinusoidal

2
2
2
2

Shock (IEC 60068-2-29) Not allowed Max. 100 m/s

(330 ft./s
),
Max. 100 m/s
(330 ft./s
),

11 ms
11 ms

Free fall Not allowed 250 mm (10 in.) for weight

250 mm (10 in.) for weight

under 100 kg (220 lb)

under 100 kg (220 lb)

100 mm (4 in.) for weight

100 mm (4 in.) for weight

over 100 kg (220 lb)

over 100 kg (220 lb)

Technical data

112

Materials

Drive enclosure • PC/ABS 2.5 mm, colour NCS 1502-Y (RAL 90021 / PMS 420 C)

• hot-dip zinc coated steel sheet 1.5 to 2 mm, thickness of coating 100 micrometres

• extruded aluminium AlSi

Package Plywood, 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.

Applicable standards

The drive complies with the following standards. The compliance with the European Low

Voltage Directive is verified according to standards EN 50178 and EN 60204-1.

• EN 50178 (1997) Electronic equipment for use in power installations

• EN 60204-1 (1997) Safety of machinery. Electrical equipment of machines. Part 1: General requirements.

Provisions for compliance: The final assembler of the machine is responsible for installing

- an emergency-stop device

- a supply disconnecting device.

• EN 60529: 1991
Degrees of protection provided by enclosures (IP code)

(IEC 60529)

• IEC 60664-1 (1992) Insulation coordination for equipment within low-voltage systems. Part 1: Principles,

requirements and tests.

• EN 61800-3 (2004) Adjustable speed electrical power drive systems. Part 3: EMC requirements and specific

test methods

• UL 508C UL Standard for Safety, Power Conversion Equipment, second edition

• NEMA 250 (2003) Enclosures for Electrical Equipment (1000 Volts Maximum)

• CSA C22.2 No. 14-95 Industrial control equipment

Technical data

 113

CE marking

A CE mark is attached to the drive to verify that the unit follows the provisions of the European Low

Voltage and EMC Directives (Directive 73/23/EEC, as amended by 93/68/EEC and Directive 89/336/

EEC, as amended by 93/68/EEC).

Definitions

EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to

operate without problems within an electromagnetic environment. Likewise, the equipment must not

disturb or interfere with any other product or system within its locality.

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.

Drive of category C2: drive of rated voltage less than 1000 V and intended to be installed and

commissioned only by a professional when used in the first environment. Note: A professional is a

person or organisation having necessary skills in installing and/or commissioning power drive systems,

including their EMC aspects.

Drive of category C3: drive of rated voltage less than 1000 V and intended for use in the second

environment and not intended for use in the first environment.

Drive of category C4: drive 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 (2004)] covers requirements

stated for drives.

Compliance with the EN 61800-3 (2004)

First environment (drive of category C2)

The drive complies with the standard with the following provisions:

1. The drive is equipped with EMC filter +E202.

2. The motor and control cables are selected as specified in the Hardware Manual.

3. The drive is installed according to the instructions given in the Hardware Manual.

4. Maximum cable length is 100 metres.

WARNING! The drive may cause radio interference if used in a residential or domestic environment.

The user is required to take measures to prevent interference, in addition to the requirements for CE

compliance listed above, if necessary.

Note: It is not allowed to install a drive equipped with 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

114

Second environment (drive of category C3)

The drive complies with the standard with the following provisions:

1. The drive is equipped with EMC filter +E200. See also page 60.

2. The motor and control cables are selected as specified in the Hardware Manual.

3. The drive is installed according to the instructions given in the Hardware Manual.

4. Maximum cable length is 100 metres.

WARNING! A drive of category C3 is not intended to be used on a low-voltage public network which

supplies domestic premises. Radio frequency interference is expected if the drive is used on such a

network.

Second environment (drive of category C4)

If the provisions under Second environment (drive of category C3) cannot be met, e.g. the drive cannot

be equipped with EMC filter +E200 when installed to an IT (unearthed) network, the requirements of the

EMC Directive can be met as follows:

1. It is ensured that no excessive emission is propagated to neighbouring low-voltage networks. In

some cases, the inherent suppression in transformers and cables is sufficient. If in doubt, a supply

transformer with static screening between the primary and secondary windings can be used.

Medium voltage network

Supply transformer

Neighbouring network
Static screen

Point of measurement

Low voltage
Low voltage

Equipment

Drive

(victim)

Equipment
Equipment

2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available

from the local ABB representative.

3. The motor and control cables are selected as specified in the Hardware Manual.

4. The drive is installed according to the instructions given in the Hardware Manual.

WARNING! A drive of category C4 is not intended to be used on a low-voltage public network which

supplies domestic premises. Radio frequency interference is expected if the drive is used on such a

network.

Machinery Directive

The drive complies with the European Union Machinery Directive (98/37/EC) requirements for an

equipment intended to be incorporated into machinery.

Technical data

 115

“C-tick” marking

“C-tick” marking is required in Australia and New Zealand. A “C-tick” mark is attached to each drive in

order to verify compliance with the relevant standard (IEC 61800-3 (2004) – Adjustable speed electrical

power drive systems. Part 3: EMC requirements and 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.

Drive of category C2: drive of rated voltage less than 1000 V and intended to be installed and

commissioned only by a professional when used in the first environment. Note: A professional is a

person or organisation having necessary skills in installing and/or commissioning power drive systems,

including their EMC aspects.

Drive of category C3: drive of rated voltage less than 1000 V and intended for use in the second

environment and not intended for use in the first environment.

Drive of category C4: drive 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 IEC 61800-3

First environment (drive of category C2)

The drive complies with the limits of IEC 61800-3 with the following provisions:

1. The drive is equipped with EMC filter +E202.

2. The drive is installed according to the instructions given in the Hardware Manual.

3. The motor and control cables used are selected as specified in the Hardware Manual.

4. Maximum cable length is 100 metres.

Note: The drive must not be equipped with 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

116

Second environment (drive of category C3)

The drive complies with the standard with the following provisions:

1. The drive is equipped with EMC filter +E200. See also page 60.

2. The motor and control cables are selected as specified in the Hardware Manual.

3. The drive is installed according to the instructions given in the Hardware Manual.

4. Maximum cable length is 100 metres.

WARNING! A drive of category C3 is not intended to be used on a low-voltage public network which

supplies domestic premises. Radio frequency interference is expected if the drive is used on such a

network.

Second environment (drive of category C4)

If the provisions under Second environment (drive of category C3) cannot be met, e.g. the drive cannot

be equipped with EMC filter +E200 when installed to an IT (unearthed) network, the requirements of the

EMC Directive can be met as follows:

1. It is ensured that no excessive emission is propagated to neighbouring low-voltage networks. In

some cases, the inherent suppression in transformers and cables is sufficient. If in doubt, a supply

transformer with static screening between the primary and secondary windings can be used.

Medium voltage network

Supply transformer

Neighbouring network
Static screen

Point of measurement

Low voltage
Low voltage

Equipment

Drive

(victim)

Equipment
Equipment

2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available

from the local ABB representative.

3. The motor and control cables are selected as specified in the Hardware Manual.

4. The drive is installed according to the instructions given in the Hardware Manual.

WARNING! A drive of category C4 is not intended to be used on a low-voltage public network which

supplies domestic premises. Radio frequency interference is expected if the drive is used on such a

network.

Technical data

 117

UL/CSA markings

The ACS800-U31 and ACS800-31 are C-UL US listed. CSA marking is pending.

UL

The drive is suitable for use on a circuit capable of delivering not more than 65 kA rms symmetrical

amperes at the drive nominal voltage (600 V maximum for 690 V units) when protected by T class

fuses.

The drive provides overload protection in accordance with the National Electrical Code (US). See

ACS800 Firmware Manual for setting. Default setting is off, must be activated at start-up.

The drives are to be used in a heated indoor controlled environment. See section Ambient conditions

for specific limits.

Equipment warranty and liability

The manufacturer warrants the equipment supplied against defects in design, materials and

workmanship for a period of twelve (12) months after installation or twenty-four (24) months from date

of manufacturing, whichever first occurs. The local ABB office or distributor may grant a warranty period

different to the above and refer to local terms of liability as defined in the supply contract.

The manufacturer is not responsible for

• any costs resulting from a failure if the installation, commissioning, repair, alternation, or ambient

conditions of the drive do not fulfil the requirements specified in the documentation delivered with

the unit and other relevant documentation.

• units subjected to misuse, negligence or accident

• units comprised of materials provided or designs stipulated by the purchaser.

In no event shall the manufacturer, its suppliers or subcontractors be liable for special, indirect,

incidental or consequential damages, losses or penalties.

This is the sole and exclusive warranty given by the manufacturer with respect to the equipment and is

in lieu of and excludes all other warranties, express or implied, arising by operation of law or otherwise,

including, but not limited to, any implied warranties of merchantability or fitness for a particular purpose.

If you have any questions concerning your ABB drive, please contact the local distributor or ABB office.

The technical data, information and specifications are valid at the time of printing. The manufacturer

reserves the right to modifications without prior notice.

Technical data

118

Technical data

 119

Dimensional drawings

The dimensions are given in millimetres and [inches].

Dimensional drawings

 120

US gland/conduit plate

Diameters of knock-out holes:

50 mm [1.97 in.], 22.7 mm

Dimensional drawings

[.89 in.]. The unit is UL type 1

when equipped with the US

gland plate.
Frame size R5 (IP21, UL type open, UL type 1)

68406200 A

 US gland/conduit

plate

Diameters of knock-

out holes: 63.5 mm

[2.50 in.], 22.7 mm

[.89 in.]. The unit is

UL type 1 when

equipped with the

US gland plate.
Frame size R6 (IP21, UL type open, UL type 1)

68405726 A

Dimensional drawings

121

122

Dimensional drawings

 123

Resistor braking

What this chapter contains

This chapter describes how to select, protect and wire external brake choppers and

resistors for the drive. The chapter also contains installation instructions and the

technical data.

How to select the correct drive/chopper/resistor combination

Refer to NBRA-6xx Braking Choppers Installation and Start-up Guide

[3AFY58920541 (English)].

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.

Resistor braking

124

External brake chopper and resistor(s) for the ACS800-31/U31

The nominal ratings for dimensioning the brake resistors for the ACS800-31 and

ACS800-U31 are given below at an ambient temperature of 40°C (104°F).

ACS800-31
Chopper
Brake resistor Cable Pbrmax
Degree of protection

ACS800-U31
type
Type R E

R
Rcont
No. of

P
Chopper Resistor

type
elements
2

ohm kJ kW mm
kW

Three-phase supply voltage 380 V, 400 V or 415 V

-0016-3 NBRA-653 SACE15RE22 22 420 2 4 3x6+6 14.4 IP54 IP21

-0020-3 NBRA-656 SACE15RE13 13 435 2 4 3x6+6 26.9 IP00 IP21

-0025-3 NBRA-656 SACE15RE13 13 435 2 4 3x6+6 26.9 IP00 IP21

-0030-3 NBRA-656 SAFUR90F575 8 1800 4.5 9 3x25+16 52.8 IP00 IP00

-0040-3 NBRA-656 SAFUR90F575 8 1800 4.5 9 3x25+16 52.8 IP00 IP00

-0050-3 NBRA-656 SAFUR90F575 8 1800 4.5 9 3x25+16 52.8 IP00 IP00

-0060-3 NBRA-656 SAFUR80F500 6 2400 6 12 3x35+16 65.6 IP00 IP00

-0070-3 NBRA-656 SAFUR125F500 4 3600 9 18 3x35+16 94.2 IP00 IP00

-0100-3 NBRA-657 SAFUR125F500 4 3600 9 18 3x70+35 94.2 IP00 IP00

Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V

-0020-5 NBRA-653 SACE15RE22 22 420 2 4 3x6+6 18.5 IP54 IP21

-0025-5 NBRA-656 SACE15RE13 13 435 2 4 3x6+6 31.4 IP00 IP21

-0030-5 NBRA-656 SACE15RE13 13 435 2 4 3x6+6 31.4 IP00 IP21

-0040-5 NBRA-656 SAFUR90F575 8 1800 4.5 9 3x25+16 62.6 IP00 IP00

-0050-5 NBRA-656 SAFUR90F575 8 1800 4.5 9 3x25+16 62.6 IP00 IP00

-0060-5 NBRA-656 SAFUR90F575 8 1800 4.5 9 3x25+16 62.6 IP00 IP00

-0070-5 NBRA-656 SAFUR80F500 6 2400 6 12 3x35+16 88.4 IP00 IP00

-0100-5 NBRA-656 SAFUR80F500 6 2400 6 12 3x35+16 88.4 IP00 IP00

-0120-5 NBRA-657 SAFUR125F500 4 3600 9 18 3x70+16 122.1 IP00 IP00

00184674 E

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

R
Short energy pulse that the resistor assembly withstands every 400 seconds. This energy will heat the resistor element from 40 °C

(104 °F) to the maximum allowable temperature.

Rcont
Continuous power (heat) dissipation of the resistor when placed correctly. Energy E

P
R dissipates in 400 seconds.

brmax
Maximum braking power of the drive equipped with the standard chopper and resistor. The drive and the chopper will withstand this

braking power for one minute every ten minutes. Note: The braking energy transmitted to the resistor during any period

shorter than 400 seconds may not exceed E

R.

All braking choppers and resistors must be installed outside the converter module. Note: The SACE and SAFUR resistors are not UL

listed.

Resistor braking

 125

Brake chopper and resistor installation

The installation instructions for the chopper and resistor are given in NBRA-6xx

Braking Choppers Installation and Start-up Guide [3AFY58920541 (English)]. All

choppers and resistors must be installed outside the drive module in a place where

they will cool.

WARNING! The materials near the brake resistor must be non-flammable. The

surface temperature of the resistor is high. Air flowing from the resistor is hundreds

of degrees Celsius. Protect the resistor against contact.

Use the cable type used for drive input cabling (refer to chapter Technical data) to

ensure the input fuses will also protect the resistor cable. Alternatively, two-

conductor shielded cable with the same cross-sectional area can be used. The

maximum length of the resistor cable(s) is 10 m (33 ft).

Protection

It is highly recommended to equip the drive with a main contactor for safety reasons.

Wire the contactor so that it opens in case the resistor overheats. This is essential

for safety since the drive will not otherwise be able to interrupt the main supply if the

chopper remains conductive in a fault situation.

Below is a simple example wiring diagram.

L1 L2 L3

OFF

Fuses
2

1
3
5
13
3

ON

2
4
6
14
4

ACS800

U1 V1 W1

Θ
Thermal switch (standard

in ABB resistors)

K1

Resistor braking

126

Brake circuit commissioning

For Standard Application Program:

• Switch off the overvoltage control of the drive (parameter 20.05).

• Frame size R6: Check the setting of parameter 21.09. If stop by coasting is

required, select OFF2 STOP.

For the use of the brake resistor overload protection (parameters 27.02...27.05),

consult an ABB representative.

WARNING! If the drive is equipped with a brake chopper but the chopper is not

enabled by parameter setting, the brake resistor must be disconnected because the

protection against resistor overheating is then not in use.

WARNING! Parameter 95.07 LCU DC REF (V) must be set to the minimum value

(default) with brake resistors. Otherwise energy from the supply network can flow to

the brake resistor causing overheating of the resistor and damage to the equipment.

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

Resistor braking

 127

External +24 V power supply for the RMIO boards

via terminal X34

What this chapter contains

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

boards of the motor-side and line-side converters via terminal X34. For current

consumption of the RMIO board, see chapter Motor control and I/O board (RMIO).

Note: For the motor-side converter RMIO board, external power is easier to supply

via terminal X23, see chapter Motor control and I/O board (RMIO).

Parameter settings

In Standard Application Program, set parameter 16.09 CTRL BOARD SUPPLY to

EXTERNAL 24V if the RMIO board is powered from an external supply.

External +24 V power supply for the RMIO boards via terminal X34

128

Connecting +24 V external power supply

RMIO board of the motor-side converter

1. Break off the tab covering the +24 VDC power input connector with pliers.

2. Pull the connector outwards.

3. Disconnect the wires from the connector (keep the connector for later use).

4. Isolate the ends of the wires individually with insulating tape.

5. Cover the isolated ends of the wires with insulating tape.

6. Push the wires into the inside of the skeleton.

7. Connect the wires of the +24 V external power supply to the disconnected

connector:

if a two-way connector, + wire to terminal 1 and - wire to terminal 2

if a three-way connector, + wire to terminal 2 and - wire to terminal 3.

8. Plug the connector in.

X34

4
4

External +24 V power supply for the RMIO boards via terminal X34

 129

RMIO board

1
2
3

X34

+
-

7
8

1
2

Connection of a two-way

connector

RMIO board

1
2
3

X34

+
-

1
2
3

Connection of a three-way

connector

External +24 V power supply for the RMIO boards via terminal X34

130

RMIO board of the line-side converter

Frame size R5

The location of terminal X34 in the line-side converter is shown below. Connect the

external +24 V supply to the board as described in steps 2 to 8 in section RMIO

board of the motor-side converter.

Terminal X34

Frame size R6

1. Remove the top cover by releasing the retaining clip with a screw driver and

lifting the cover upwards.

2. Disconnect the DDCS communication module by undoing the fastening screws

and disconnecting the fibre optic cables. Disconnect other optional modules if

present.

3. Disconnect the control panel cable.

4. Disconnect the additional fan cable (detachable terminal) and release the strain

relief.

5. Remove the I/O terminal blocks.

6. Undo the fastening screws of the upper plastic cover.

7. Lift the cover carefully upwards by the lower sides.

8. Disconnect the control panel cable from the RMIO board.

External +24 V power supply for the RMIO boards via terminal X34

 131

9. Lift the upper plastic cover off.

10. Connect the external +24 V supply to the board as described in steps 2 to 5, 7

and 8 in section RMIO board of the motor-side converter.

11. Reconnect all disconnected cables and fasten the covers in reverse order.

6
2

5 5 5

7
7

External +24 V power supply for the RMIO boards via terminal X34

132

External +24 V power supply for the RMIO boards via terminal X34

 Dimensional drawings: 14.10.2005

3AFE68599954 Rev A EN

EFFECTIVE: 14.10.2005

ABB Oy
ABB Inc.

AC Drives
Automation Technologies

P.O. Box 184

Drives & Motors

FI-00381 HELSINKI
16250 West Glendale Drive

FINLAND
New Berlin, WI 53151

Telephone +358 10 22 11
USA

Fax +358 10 22 22681

Telephone 262 785-3200

Internet http://www.abb.com
800-HELP-365

Fax 262 780-5135