ABB ACS800 Installation Manual

ACS800

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

ACS800 Single Drive Manuals

HARDWARE MANUALS (appropriate manual is included in the

delivery)

ACS800-01/U1 Hardware Manual 0.55 to 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)

ACS800-04 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)

• 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)

PFC Application Program Firmware Manual 3AFE64649337 (English)

Extruder Control Program Supplement 3AFE64648543 (English)

Centrifuge Control Program Supplement 3AFE64667246 (English)

Traverse Control Program Supplement 3AFE64618334 (English)

Crane Control Program Firmware Manual 3BSE11179 (English)

Adaptive Programming Application Guide 3AFE64527274 (English)

OPTION MANUALS (delivered with optional equipment)

Fieldbus Adapters, I/O Extension Modules etc.

ACS800-04 and ACS800-04M Drive Modules

45 to 560 kW

ACS800-U4 Drive Modules

60 to 600 HP

Cabinet Installation

3AFE68360323 Rev A EN

EFFECTIVE: 12.11.2004

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

Table of contents

About this manual

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Other related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Categorization according to the frame size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Categorization according to the plus code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Installation, commissioning and operating flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

The ACS800-04/U4 and ACS800-04M

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

The ACS800-04/U4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

The ACS800-04M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Example configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Connections of the Drive Control Unit (RDCU) in frame sizes R7 and R8 . . . . . . . . . . . . . . . . 21

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Planning the cabinet installation

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

Cabinet construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Disposition of the devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Layout examples, door closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Layout examples, door open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Grounding of mounting structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Busbar material and joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Cabinet cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Cabinet cooling data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

IP 22 cabinet with no extra fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

IP 54 cabinet with an extra fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Table of contents

Preventing the recirculation of hot air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Outside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Cubicle heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Required free space around the drive module for cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Free space at the top of the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Free space around units with busbars on the long side (bookshelf mounting +H354) . . . . . . . 31

Free space around units with busbars on the short side (flat mounting +H360) . . . . . . . . . . . 32

When the drive module is installed in another position than vertically . . . . . . . . . . . . . . . . . . . . . . 33

Drive module of frame size R7 on its side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Drive module of frame size R7 on its back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

EMC requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Grounding of cable shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Installing the Drive Control Unit (RDCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Fastening of the control panel (CDP312R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Installing the control panel directly on the cabinet door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Control Panel Mounting Platform RPMP-11/13 (+J410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Control Panel Holder RPMP-21 (+J413) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

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

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

Moving and unpacking the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Fasten the module to the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Clamping the pedestal with the outside brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Fasten the terminals to the busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

View of output busbar connections of frame size R7 (DC and brake busbars included) . . . 43 View of output busbar connections of frame size R8 (DC and brake busbars included) . . 44

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

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

How to read this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Units with bottom exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Units with pedestal and busbars on the long side (+H354, bookshelf mounting) . . . . . . . . . . . 45

Units with pedestal and busbars on the short side (+H360, flat mounting) . . . . . . . . . . . . . . . . 45

Required tools and tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Moving and unpacking the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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

Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Assembling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Fastening the spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Fastening the top entry busbar and bottom exit shrouds (+B060) . . . . . . . . . . . . . . . . . . . . . . . 55

Top entry busbar shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Bottom exit shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Table of contents

Units with pedestal and busbars on the long side (+H354, bookshelf mounting) . . . . . . . . . 57

Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Item packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Item packages of frame size R7 with busbars on the long side . . . . . . . . . . . . . . . . . . . . . . . 58

Item packages of frame size R8 with busbars on the long side . . . . . . . . . . . . . . . . . . . . . . 64

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

Working order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Connecting the DC busbars to the pedestal (+H356 and +H363 only) . . . . . . . . . . . . . . . . . . . 76

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Photos of frame size R7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Photos of frame size R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Busbars to the left- or right-hand side of the module? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Swapping the busbars of the pedestal to the other side . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Optional selection +H363 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Fastening the pedestal to the cabinet base (not for wall-mounted units) . . . . . . . . . . . . . . . . . . 80

Clamping the pedestal with the outside brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Fastening the pedestal through the holes inside the pedestal . . . . . . . . . . . . . . . . . . . . . . . . 80

Fastening the drive module by top to the cabinet frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Fastening the drive module to wall (wall-mounted units only, not for base-mounted units) . . . . 81

Requirements for protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Requirements for the wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Fastening the output busbars and PE terminal and sliding the module in . . . . . . . . . . . . . . . . . 86

View of output busbar connections of frame size R7 (DC and brake busbars included) . . . 87

View of output busbar connections of frame size R8 (DC and brake busbars included) . . . 88

Fastening the drive module to the pedestal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Fastening the shrouds in frame size R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Top entry busbar shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Vertical busbar shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Units with pedestal and busbars on the short side (+H360, flat mounting) . . . . . . . . . . . . . . 91

Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Item packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Item packages of frame size R7 with busbars on the short side . . . . . . . . . . . . . . . . . . . . . . 92

Item packages of frame size R8 with busbars on the short side . . . . . . . . . . . . . . . . . . . . . 98

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

Working order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Swapping the pedestal output busbars to the left-hand side . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Connecting the DC busbars to the pedestal (+H360 +H356 only) . . . . . . . . . . . . . . . . . . . . . . 107

Required parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Preparing the adapter (+H360 +H356 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Required parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Fastening the adapter to the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Fastening the drive module to the pedestal via the adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Connecting the output busbars on the short side of the module . . . . . . . . . . . . . . . . . . . . . . . 111

Procedure for frame size R7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Procedure frame size R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Table of contents

Checking the installation

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Cabinet construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Instrumentation, busbars and cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Groundings and protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Labels, switches, fuses and doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Dimensional drawings

Frame size R7 without pedestal (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Frame size R7 with bottom exit (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Frame size R7 with bottom exit and top entry and bottom exit shrouds (mm) . . . . . . . . . . . . . . 122

Frame size R7 with busbars on the left side (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Frame size R7 with DC busbars on both sides (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Frame size R7 pedestal busbars on the long side (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Frame size R7 with busbars on the short side (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Frame size R8 without pedestal (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Frame size R8 with busbars on the left side (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Frame size R8 with top entry and vertical busbar shrouds (mm) . . . . . . . . . . . . . . . . . . . . . . . . . 129

Frame size R8 with busbars on both sides (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Frame size R8 pedestal busbars on the long side (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Frame size R8 with busbars on the short side (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Wall mounting spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Frame size R7 bottom exit kit (+H352) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Frame size R7 top entry busbar shroud and bottom exit shroud (+B060) . . . . . . . . . . . . . . . . . . 135

Control Panel Holder RPMP-21 (+J413) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Drive Control Unit (RDCU-02) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

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

Frame size R7 without pedestal (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Frame size R7 with bottom exit (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Frame size R7 with bottom exit and top entry and bottom exit shrouds (inches) . . . . . . . . . . 141

Frame size R7 with busbars on the left side (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Frame size R7 with busbars on both sides (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Frame size R7 pedestal busbars on the long side (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Frame size R7 with busbars on the short side (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Frame size R8 without pedestal (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Frame size R8 with busbars on the left side (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Frame size R8 with top entry and vertical busbar shrouds (inches) . . . . . . . . . . . . . . . . . . . . 148

Frame size R8 with busbars on both sides (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Frame size R8 pedestal busbars on the long side (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Frame size R8 with busbars on the short side (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Circuit diagrams

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Table of contents

Assembly drawings

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Adding UDC+/R+, UDC- and R- busbars to the pedestal (frame size R7, +H356+H360) . . . . . . 156

Adding UDC+/R+, UDC- and R- busbars to the adapter (frame size R7, +H356+H360) . . . . . . . 157

Adding UDC+/R+, UDC- and R- busbars to the pedestal (frame size R8, +H356+H360) . . . . . . 158

Adding UDC+/R+, UDC- and R- busbars to the adapter (frame size R8, +H356+H360) . . . . . . . 159

Table of contents

About this manual

What this chapter contains

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

Target audience

This manual is intended for people who plan the installation, and install the drive module into a user-defined cabinet. Read the manual before the installation work. The reader is expected to know the fundamentals of electricity, wiring, electrical components and electrical schematic symbols.

The manual is written for readers worldwide. Both SI and imperial units are shown. Special US instructions for installations within the United States that must be installed per the National Electrical Code and local codes are marked with (US).

Safety

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

Manual [3AFE64671006 (English)] when installing, operating and servicing the drive. If ignored, physical injury or death may follow, or damage may occur to the drive, the motor or driven equipment. Read the safety instructions before you work on the unit.

Other related manuals

See ACS800-04/04M/U4 Hardware Manual [3AFE64671006 (English)] for information concerning the drive module such as

• safety

• planning the electrical installation

• electrical installation

• motor control and I/O board (RMIO)

• maintenance

• technical data

• resistor braking.

About this manual

For installation instructions of optional equipment, see their manuals.

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

Categorization according to the frame size

The instructions, technical data and dimensional drawings which concern only certain frame sizes are marked with the symbol of the frame size R7 or R8. The frame size is not marked on the drive designation label. To identify the frame size of your drive, see the rating tables in chapter Technical data in ACS800-04/04M/U4 Hardware Manual [3AFE64671006 (English)].

Categorization according to the plus code

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

ACS800-04/U4 and ACS800-04M under Type code.

The chapters of this manual are briefly described below.

About this manual introduces this manual.

The ACS800-04/U4 and ACS800-04M describes the drive module.

Planning the cabinet installation instructs on general cabinet design, gives layout

examples, free space requirements around the drive module for cooling and cabinet cooling data.

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

mount a pre-assembled drive module into a cabinet.

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

assemble the drive from the assembly kits.

Checking the installation helps in checking the mechanical and electrical installation

of the drive.

Dimensional drawings contains the dimensional drawings of the drive module.

Circuit diagrams shows an example circuit diagram for employing the Prevention of

Unexpected Start function (+Q950).

Assembly drawings contains a few step-by-step assembly drawings.

About this manual

Installation, commissioning and operating flowchart

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

Hardware Manual

[3AFE64671006 (English)

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

tables / NEMA ratings

Plan the installation.

Check the ambient conditions, ratings, required cooling air flow, input power connection, compatibility of the motor, motor connection, and other technical data.

Unpack and check the units.

Check that all necessary optional modules and equipment are present and correct.

Only intact units may be started up.

Assemble and install the drive module into the cabinet.

Install the RDCU drive control unit. - See RDCU Drive Control Unit

Planning the cabinet installation

If optional equipment is included, see its manuals.

Mechanical installation of preassembled units (ACS800-04/U4) or Mechanical installation of non-preassembled units (ACS800-04M)

If the converter has been nonoperational for more than one year, the converter DC link capacitors need to be reformed. Ask ABB for instructions.

Mechanical installation of preassembled units (ACS800-04/U4) or Mechanical installation of non-preassembled units (ACS800-04M)

Technical data

Planning the electrical installation

Hardware Manual

[3AFE64636324 (English)]

Check the installation. Checking the installation -

Electrical installation - Safety, Planning the electrical

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

Commissioning and operating the drive - See the appropriate firmware

manual.

About this manual

Inquiries

Address any inquiries about the product to the local ABB representative, quoting the type code and the serial number of the unit. If the local ABB representative cannot be contacted, address inquiries to the manufacturing facility.

About this manual

The ACS800-04/U4 and ACS800-04M

What this chapter contains

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

The ACS800-04/U4

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

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

Fastening points

Motor cable terminals

Optional brake and DC

busbars and terminals

PE terminal

Alternative output cable

terminals (when no

vertical busbars are used)

Input cable terminals

Fastening points

Front cover

Additional holes for fastening the cable terminals

Pedestal

Drive Control Unit

(RDCU)

Fastening bracket

The ACS800-04/U4 and ACS800-04M

The ACS800-04M

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

Example configurations

Frame size R7

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

Frame size R7 with bottom exit (optional top entry busbar shroud and bottom exit shroud included). Output busbars are located at the base of the module.

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

Frame size R8

Drive Control Unit (RDCU)

Output busbars on the short side of the module

The ACS800-04/U4 and ACS800-04M

Type designation label

The type designation label includes an IEC and NEMA rating, C-UL US, and CSA markings, a type code and a serial number, which allow individual recognition of each unit. The first digit of the serial number refers to the manufacturing plant. The next four digits refer to the unit’s manufacturing year and week respectively. The remaining digits complete the serial number so that there are no two units with the same serial number.

The type designation label is located on the front cover and the serial number label inside the unit. Example labels are shown below.

The ACS800-04/U4 and ACS800-04M

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. ACS800-040170-5). The optional selections are given thereafter, separated by plus signs (e.g. +E202). The main selections are described below. Not all selections are available for all types. For more information, refer to ACS800 Ordering Information (EN code: 64556568, available on request).

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

Selection Alternatives Product series ACS800 product series Type 04 Drive module. When no options are selected: 6-pulse diode input bridge, IP 00, top

entry, side exit, RDCU drive control unit, no control panel, no EMC filter, Standard Application Program, boards without coating, pedestal with output on the long side, output busbar set for motor, base and wall mounting brackets, one set of manuals. Pre-assembled unit.

U4 Drive module (USA). When no options are selected: 6-pulse diode bridge, open

chassis, top entry, side exit, no control panel, no EMC filter, US version of the Standard Application Program (three-wire start/stop as default setting), common mode filter in frame size R8, boards without coating, pedestal with output on the long side, output busbar set for motor, base and wall mounting brackets, one set of manuals. Pre-assembled unit.

Size Refer to Technical data: IEC ratings or NEMA ratings. Voltage range

(nominal rating in bold)

+ options

Resistor braking D150 brake chopper and busbars for brake resistor and DC connection Filter E210 EMC/RFI filter for second environment TN/IT (grounded/ungrounded) system

Pedestal and output busbars

Control panel J400 control panel including a 3-metre panel connection cable

Fieldbus K... Refer to ACS800 Ordering Information (EN code: 64556568). I/O L... Application program N... Language of manual R... Specialities P901 coated boards

2 208/220/230/240 VAC 3 380/400/415 VAC 5 380/400/415/440/460/480/500 VAC 7 525/575/600/690 VAC

E208 common mode filter 0H354 no pedestal

J410 RPMP-11/13 control panel mounting platform kit including a 3-metre panel connection

cable but no control panel

J413 RPMP-21 control panel holder

The ACS800-04/U4 and ACS800-04M

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

Selection Alternatives Product series ACS800 product series Typ e 04M Drive module. When no options are selected: 6-pulse diode input bridge, IP 00, top

entry, RDCU drive control unit, Standard Application Program, boards without coating, one set of manuals. No pedestal, no output busbars, no control panel, no EMC filter. Delivered as kits.

Size Refer to Technical data: IEC ratings. Voltage range (nominal rating in bold)

+ options

Shrouds B060 Frame size R7:

Resistor braking D150 brake chopper Filter E202 EMC/RFI filter for first environment TN (grounded) system, restricted (the A limits)

Pedestal and output busbars

Control panel J400 control panel including a 3-metre panel connection cable

Fieldbus K... Refer to ACS800 Ordering Information (EN code: 64556568). I/O L... Application program N... Language of manual R... Specialities P901 coated boards Safety features Q950 Prevention of Unexpected Start, 500 mm (19.68 in.) cable outside the drive module in

2 208/220/230/240 VAC 3380/400/415 VAC 5 380/400/415/440/460/480/500 VAC 7 525/575/600/690 VAC

clear plastic shrouds for bottom exit kit (+H352) and input terminals. Frame size R8: bookshelf mounting (+H354)

E210 EMC/RFI filter for second environment TN/IT (grounded/ungrounded) system E208 common mode filter H352 bottom exit kit for frame size R7 H354 pedestal with output on the long side (bookshelf) H355 vertical busbars and support brackets for AC output connection H356 pedestal (and adapter with +H360) busbar kit for brake resistor and DC connection H360 pedestal with output on the short side (flat) H362 vertical busbars (and support brackets with +H360) for DC output connection H363 busbar kit for DC connection on both long sides of the pedestal (+H356 required, not

available for +H360)

J410 RPMP-11/13 control panel mounting platform kit including a 3-metre panel connection

cable but no control panel

J413 RPMP-21 control panel holder

frame size R7, 600 mm (23.62 in.) cable outside the drive module in frame size R8.

clear plastic shrouds for vertical busbars and input terminals in

The ACS800-04/U4 and ACS800-04M

Control interfaces

This diagram shows the control interfaces and the main circuit of the drive.

External control via analogue/digital inputs and outputs

Input power

Motor control and I/O board (RMIO)

R- UDC+ UDC-

R+

Optional module 1: RMBA, RAIO, RDIO, RDNA, RLON, RIBA, RPBA, RCAN, RCNA, RMBP, RETA or RTAC

Optional module 2: RTAC, RAIO or RDIO

DDCS communication option module: RDCO-01, RDCO-02 or RDCO-03

Brake chopper (optional)

Output power

The ACS800-04/U4 and ACS800-04M

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

ACS800-04 drive module

AINT

(

”

APOW

Protective tube

3 m (118 in.)

(

”

)

Shield

2100 mm (83 in.)

)

”

(

Control panel mounting platform kit (RPMP-12/13, optional)

Control panel CDP312R (optional)

Operation

This table describes the operation of the main circuit in short.

Shielded 6-pin modular connector

3 m (11 8 in.)

To RM I O

External control connections to RMIO board

Drive control unit RDCU which contains motor control and I/O board RMIO

Component Description

six-pulse rectifier converts the three-phase AC voltage to DC voltage

capacitor bank energy storage which stabilizes the intermediate circuit DC voltage

six-pulse IGBT inverter converts the DC voltage to AC voltage and vice versa. The motor

operation is controlled by switching the IGBTs.

The ACS800-04/U4 and ACS800-04M

Printed circuit boards

The drive contains the following printed circuit boards as standard:

• main circuit board (AINT)

• motor control and I/O board (RMIO) with a fibre optic link to the AINT board

• input bridge control board (AINP)

• input bridge protection board (AIBP) which includes snubbers for the thyristors and varistors

• power supply board (APOW)

• gate driver control board (AGDR)

• diagnostics and panel interface board (ADPI)

• brake chopper control board (ABRC) with option +D150

Motor control

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

The ACS800-04/U4 and ACS800-04M

Planning the cabinet installation

What this chapter contains

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

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

Cabinet construction

The cabinet frame must be sturdy enough to carry the weight of the drive components, control circuitry and other equipment installed in it.

The cabinet must protect the converter module against contact and meet the requirements for dust and humidity, see chapter Technical data in ACS800-04/04M/ U4 Hardware Manual [3AFE64671006 (English)].

Disposition of the devices

For easy installation and maintenance, a spacious layout is recommended. Sufficient cooling air flow, obligatory clearances, cables and cable support structures all require space.

The control boards must not be installed near main circuits or hot parts.

The following sections show a few layout examples. For example layouts in Rittal TS 8 cabinet, refer to ACS800-04/U4 Rittal TS 8 Cabinet Installation [3AFE68372330 (English)].

Planning the cabinet installation

Layout examples, door closed

IP 22

IP 54

1a Air inlet for the converter module 1b Air inlet for the other equipment 2a Air outlet for the converter module 2b Air outlet for the other equipment

2c Air outlet for the converter module and the

other equipment, an extra exhaust fan

3 Converter control panel (connected to the

RMIO board in the RDCU unit inside the cabinet)

4 Contactor control switch and emergency

stop switch (connected to the contactor control circuit inside the cabinet)

5 Operating handle of the disconnector

Roof air flow viewed from top

Planning the cabinet installation

Layout examples, door open

IP 22

IP 54

1 Supporting frame of the cabinet 2 Air baffles that separate the cool and hot

areas (leak-proof lead-throughs)

3 Input power cable including the protective

conductors to cabinet grounding (PE)

4 Disconnector and fuses

5 Contactor 6 Converter module 7 Motor cable including the grounding

conductors

8 Drive Control Unit RDCU (includes RMIO

board)

9 External control cables

IP 22

Air flow to the roof

IP 54

Air flow through the module

Fan

See also section Required free space around the drive

module for cooling.

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

Planning the cabinet installation

Grounding of mounting structures

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

Busbar material and joints

Tin-plated copper is recommended but aluminium can also be used.

Before joining aluminium busbars, remove the oxide layer and apply suitable antioxidant joint compound.

Tightening torques

The following table applies to zinc and chrome platings, and grade 8.8 screws (with or without joint compound).

Screw size Torque

Soft aluminium Alloyed aluminium and

copper

Nm lbf ft Nm lbf ft M5 3.5 2.6 3.5 2.6 M6 6 4.4 9 6.6 M8 17 12.5 20 14.8 M10 35 25.8 40 29.5 M12 55 40.6 70 51.6 M16 130 95.9 180 132.8

Cabinet cooling

The installation site must be sufficiently ventilated.

The cabinet must have enough free space for the components to ensure sufficient cooling. Observe the minimum clearances given for each component.

The heat dissipated by cables and other additional equipment must also be ventilated.

The air inlets and outlets must be equipped with gratings that

• guide the air flow

• protect against contact

• prevent water splashes from entering the cabinet.

Planning the cabinet installation

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

Air outlet

Air inlet

The internal cooling fans of the converter modules and reactors/chokes are usually sufficient to keep the component temperatures low enough in IP 22 cabinets.

In IP 54 cabinets, thick filter mats are used to prevent water splashes from entering the cabinet. This entails the installation of additional cooling equipment, such as a hot air exhaust fan.

Arrange the cooling air flow through the converter module so that the requirements given in chapter Technical data in ACS800-04/04M/U4 Hardware Manual [3AFE64671006 (English)] are met:

• cooling air flow

Note:

The figures apply to continuous nominal load. If the load is cyclic or less than nominal, less

cooling air is required.

• allowed ambient temperature.

See section Cabinet cooling data for:

• allowed temperature rise inside the cabinet

• allowed pressure drop over the cabinet that the module fan can overcome

• air inlet and outlet sizes required for the module cooling and recommended filter material (if used).

Planning the cabinet installation

Cabinet cooling data

IP 22 cabinet with no extra fan

The table below shows the data the IP 22 cabinet should meet to ensure efficient cooling of the converter module. No extra fan is used. The pressure drop over the cabinet is the additional counterpressure that the module fan is capable of overcoming while still maintaining the required air flow through the module.

Frame

size

R7 30 300 30 288×292+688×521 airTex G150 398×312 (2 pcs) R8 30 300 45 288×292+688×521 airTex G150 398×312 (2 pcs)

Temp. rise Pressure drop Cabinet air inlet Min. cabinet air

Over module Over module Over cabinet Min. size Filter

°C Pa Pa mm by Luftfilter mm

* size when the outlet is located on the cabinet roof

outlet size*

00096931

IP 54 cabinet with an extra fan

The table below shows the data the IP 54 cabinet should meet to ensure efficient cooling of the converter module. An extra fan is used. The pressure drop over the cabinet is the counterpressure the extra fan must overcome. The given fan types and filter materials are examples. Corresponding products by another manufacturer may be used as well. See the manufacturer’s Internet site for the detailed specification.

Frame

Size

R7 30 250* RB2C-225/088 K093 or

R8 30 250* RH35M-4EK.2F.1R by

Temp. rise Pressure drop Extra fan type Air inlet and outlet filter by Luftfilter

Over module Over cabinet Min. inlet (door) Min. outlet (roof)

°C Pa mm mm

R2E225-AU64 by ebm

Ziehl-Abegg or RB4T-

355/170 by ebm

airComp 300-50

288×292 + 688×521 airComp 300-50

288×292 + 688×521

airTex G150

398×312 (2 pcs)

airTex G150

398×312 (2 pcs)

00096931

* inlet filter 50 % unclean

Planning the cabinet installation

Preventing the recirculation of hot air

Vertical air baffle

Air flow out

Converter module

Converter cubicle from aboveConverter cubicle from side

A - A

Converter module

Horizontal air baffle

Outside the cabinet

Prevent hot air circulation outside the cabinet by leading the outcoming hot air away from the area where the inlet air to the cabinet is taken. Possible solutions are listed below:

• gratings that guide air flow at the air inlet and outlet

• air inlet and outlet at different sides of the cabinet

• cool air inlet in the lower part of the front door, and an extra exhaust fan on the roof of the cabinet.

Inside the cabinet

Prevent hot air circulation inside the cabinet with e.g. leak-proof air baffles at the positions shown in the diagrams in section Required free space around the drive

module for cooling. No gaskets are usually required.

Cubicle heaters

Air flow in max. 40°C (104 °F)

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

Planning the cabinet installation

Required free space around the drive module for cooling

Free space at the top of the drive module

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

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

FlatBookshelf