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

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Summary of Contents for ABB ACS800

  • Page 1 ACS800 Hardware Manual ACS800-04 and ACS800-04M Drive Modules (45 to 560 kW) ACS800-U4 Drive Modules (60 to 600 HP)
  • Page 2: Acs800 Single Drive Manuals

    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...
  • Page 3 ACS800-04 and ACS800-04M Drive Modules 45 to 560 kW ACS800-U4 Drive Modules 60 to 600 HP Hardware Manual 3AFE64671006 Rev E EN EFFECTIVE: 19.11.2004  2004 ABB Oy. All Rights Reserved.
  • Page 5: Safety Instructions

    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, ACS800-02/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.
  • Page 6: Installation And Maintenance Work

    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.
  • Page 7: Grounding

    In addition, connect the cable shields to protective earth (PE) in order to meet safety regulations. ACS800-04 (45 to 560 kW) in first environment: make a 360° high frequency grounding of motor cable entries at the cabinet lead-through. (ACS800-02: 360° high frequency grounding of cable entries is not required at the drive end.)
  • Page 8: Mechanical Installation And Maintenance

    Handle the unit carefully. • ACS800-01, ACS800-11: 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.
  • Page 9: Printed Circuit Boards

    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:...
  • Page 10: Operation

    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.
  • Page 11: Permanent Magnet Motor

    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.
  • Page 12 Safety instructions...
  • Page 13: Table Of Contents

    ACS800 Single Drive Manuals ........
  • Page 14 Emergency stop devices ............39 ACS800-02/U2 with enclosure extension and ACS800-07/U7 ......39 Restarting after an emergency stop .
  • Page 15 To which products this chapter applies ..........59 Note for the ACS800-02 with enclosure extension and the ACS800-07 ..... 59 Note on external power supply .
  • Page 16 RMIO board specifications ............62 Analogue inputs .
  • Page 17 To which products this chapter applies ..........95 Availability of brake choppers and resistors for the ACS800 ......95 How to select the correct drive/chopper/resistor combination .
  • Page 18 Table of contents...
  • Page 19: About This Manual

    Common chapters for several products Chapters Planning the electrical installation, Motor control and I/O board (RMIO) Resistor braking apply to the ACS800-01/U1, ACS800-02/U2, ACS800-04/04M/U4 and ACS800-07/U7 types up to -0610-x. Safety instructions apply to the ACS800-01/ U1, ACS800-02/U2 and ACS800-04/04M/U4.
  • Page 20: Contents

    The chapter also contains technical data. Other related manuals Refer to ACS800-04/04M/U4 Cabinet Installation [3AFE68360323 (English)] for information concerning the drive module such as • dimensional drawings of the drive module •...
  • Page 21: Inquiries

    Appropriate 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...
  • Page 22 About this manual...
  • Page 23: The Acs800-04/U4 And Acs800-04M

    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.
  • Page 24: The 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 Output busbars on the short Motor and brake busbars on the...
  • Page 25: Type Designation Label

    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...
  • Page 26: Type Code

    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. ACS800-04- 0170-5). 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.
  • Page 27 Type code for ACS800-04M non-pre-assembled units (delivered as kits) Selection Alternatives Product series ACS800 product series Type 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.
  • Page 28: Control Interfaces

    RCAN, RCNA, RMBP, RETA or RTAC (RMIO) Optional module 2: RTAC, RAIO or External control via RDIO analogue/digital inputs and outputs DDCS communication option module: RDCO-01, RDCO-02 or RDCO-03 Input power Output power Brake chopper (optional) R- UDC+ UDC- The ACS800-04/U4 and ACS800-04M...
  • Page 29: Connections Of The Drive Control Unit (Rdcu) In Frame Sizes R7 And R8

    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...
  • Page 30: Printed Circuit Boards

    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...
  • Page 31: Mechanical Installation

    This chapter describes the mechanical installation of the drive cabinet generally. Follow the specific instructions given by the panel builder. For the mechanical assembly and dimensional drawings of the drive module, refer to ACS800-04/04M/ U4 Cabinet Installation [3AFE68360323 (English)]. Before installation...
  • Page 32: Cable Channel In The Floor Below The Cabinet

    Cable channel in the floor below the cabinet When a cable channel is constructed below the cabinet, ensure that cabinet weight lies on the sections which the floor carries. Example cabinet frame viewed from above Example cabinet: side view Cables Prevent the cooling air flow from the cable channel to the cabinet by bottom plates.
  • Page 33: Planning The Electrical Installation

    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.
  • Page 34: Protecting The Motor Insulation And Bearings

    The stress on motor insulation can be avoided by using optional ABB du/dt filters. du/dt filters also reduce bearing currents.
  • Page 35: Requirements Table

    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.
  • Page 36 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.
  • Page 37: Permanent Magnet Synchronous Motor

    Supply connection Disconnecting device (disconnecting means) ACS800-01, ACS800-U1, ACS800-11, ACS800-U11, ACS800-02, 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.
  • Page 38: Thermal Overload And Short-Circuit Protection

    When placed at the distribution board, standard gG (US: CC or T for the ACS800- U1; T or L for the ACS800-U2 and ACS800-U4) fuses 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.
  • Page 39: Circuit Breakers

    Circuit breakers 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.
  • Page 40: Prevention Of Unexpected Start

    Prevention of Unexpected Start The drive 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.
  • Page 41: Selecting The Power Cables

    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.
  • Page 42: Alternative Power Cable Types

    Alternative power cable types Power cable types that can be used with the drive are represented below. Recommended Symmetrical shielded cable: three phase conductors A separate PE conductor is required if the conductivity and a concentric or otherwise symmetrically of the cable shield is < 50 % of the conductivity of the constructed PE conductor, and a shield phase conductor.
  • Page 43: Additional Us Requirements

    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).
  • Page 44: Equipment Connected To The Motor Cable

    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.
  • Page 45: Protecting The Relay Output Contacts And Attenuating Disturbances In Case Of Inductive Loads

    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.
  • Page 46: Selecting The Control Cables

    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...
  • Page 47: Connection Of A Motor Temperature Sensor To The Drive I/O

    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. 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.
  • Page 48: Control Cable Ducts

    A diagram of the cable routing is shown below. Motor cable Drive min 300 mm (12 in.) Power cable Input power cable Motor cable 90 ° min 200 mm (8 in.) min 500 mm (20 in.) Control cables Control cable ducts 24 V 230 V 24 V 230 V...
  • Page 49: Electrical Installation

    Electrical installation What this chapter contains This chapter instructs in the cabling of the drive. Warnings WARNING! Only qualified electricians are allowed to carry out the work described in this chapter. Follow the Safety instructions on the first pages of this manual. Ignoring the safety instructions can cause injury or death.
  • Page 50: It (Ungrounded) Systems

    (ungrounded systems). If the drive is equipped with EMC filter +E202, disconnect the filter before connecting the drive to an ungrounded system. For detailed instructions on how to do this, please contact your local ABB representative. WARNING! If a drive with EMC filter +E202 is installed on an IT system [an...
  • Page 51: Example Wiring Diagram

    Example wiring diagram The diagram below presents an example for the main wiring. Note that the diagram includes optional components which are not included in a basic delivery (marked *) and equipment not available as options (marked **). Electrical installation...
  • Page 52: Power Cable Connection Diagram

    Power cable connection diagram Drive module OUTPUT INPUT UDC+ V1 W1 V2 W2 (PE) (PE) * For alternatives, see Planning the electrical Optional brake installation: Disconnecting resistor device (disconnecting means) Motor 1), 2) Grounding of the motor cable shield at the cabinet entry If shielded cable is used (not required but Ground the cable shield 360 degrees at the lead-through of the recommended) and the conductivity of the shield is...
  • Page 53: Grounding Of The Cable Shields

    Grounding of the cable shields To power terminals Example cable lead-through Strain relief Cable shield PE terminal of the cabinet or drive module EMC sleeve * Strip this part of the cable * Recommended Base plate for control Lead-through plate cables Strain relief...
  • Page 54: Fastening Us Cable Lugs

    Fastening US cable lugs Example mounting US cable lugs can be connected directly to the output busbars or to the terminals as follows. 1/2” bolt 1 3/4” Electrical installation...
  • Page 55: Connections Of The Rdcu

    Connections of the RDCU The RDCU drive control unit contains the RMIO board where the user’s control cables are connected. WARNING! Handle the fibre optic cables with care. When unplugging optic cables, always grab the connector, not the cable itself. Do not touch the ends of the fibres with bare hands as the fibre is extremely sensitive to dirt.
  • Page 56: Connecting The Control Cables To The Rmio Board

    Connecting the control cables to the RMIO board 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. Make a 360 degrees EMC grounding at the cabinet entry in first environment installations.
  • Page 57: Settings Of The Cooling Fan Transformer

    Settings of the cooling fan transformer The voltage transformer of the cooling fan is located at the top right-hand corner of the drive module. Remove the front cover for adjusting the settings and replace the cover after setting. Set to 220 V if the supply frequency is 60 Hz. Set to 230 V if the supply frequency is 50 Hz.
  • Page 58: Pulse Encoder Module Cabling

    Pulse encoder module cabling Clamp as close to the terminals as possible. Alternative to a) Note1: If the encoder is of unisolated As short as type, ground the encoder cable at the possible drive end only. If the encoder is Strain relief galvanically isolated from the motor with a cable tie...
  • Page 59: Motor Control And I/O Board (Rmio)

    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.
  • Page 60: External Control Connections (Non-Us)

    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. RMIO RMIO VREF- Reference voltage -10 VDC, 1 kohm <...
  • Page 61: External Control Connections (Us)

    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.
  • Page 62: Rmio Board Specifications

    RMIO board specifications Analogue inputs With Standard Application Program two programmable differential current inputs (0 mA / 4 mA ... 20 mA, R = 100 ohm) and one programmable differential voltage input (-10 V / 0 V / 2 V ... +10 V, R >...
  • Page 63: Relay Outputs

    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 %...
  • Page 64 Isolation and grounding diagram (Test voltage: 500 V AC) VREF- AGND VREF+ AGND AI1+ Common mode AI1- voltage between AI2+ channels ±15 V AI2- AI3+ AI3- AO1+ AO1- AO2+ AO2- Jumper J1 settings: DGND1 All digital inputs share a common ground.
  • Page 65: Maintenance

    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. WARNING! The drive module is heavy [frame size R7: 100 kg (220 lb), frame size R8: 200 kg (441 lb)].
  • Page 66: Maintenance Intervals

    Maintenance intervals If installed in an appropriate environment, the drive requires very little maintenance. This table lists the routine maintenance intervals recommended by ABB. Interval Maintenance Instruction Every year when stored Capacitor reforming See Reforming. Every 6 to 12 months Heatsink temperature check See Heatsink.
  • Page 67: Layout

    Layout The layout stickers of the drive are shown below. The stickers show all possible components. Not all of them are present in each delivery or described here. Components that need to be changed regularly are listed below: Designation Component Cooling fan Capacitors Code: 64572261...
  • Page 68: Heatsink

    See the appropriate ACS800 firmware manual for the actual signal which indicates the running time of the cooling fan. Replacement fans are available from ABB. Do not use other than ABB specified spare parts. Maintenance...
  • Page 69: Replacing The Fan (R7)

    Replacing the fan (R7) 1. Remove the front cover. 2. Disconnect the discharging resistor wire(s). 3. Remove the DC capacitor pack by undoing the red fixing screws and pulling the pack out. 4. Disconnect the fan supply wires (detachable connector). 5.
  • Page 70: Replacing The Fan (R8)

    Replacing the fan (R8) 1. Remove the front cover. 2. Disconnect the fan capacitor and power supply wires. 3. Undo the red fastening screws of the plastic side cover of the fan. Shift the cover to the right to free its right-hand edge and lift the cover off. 4.
  • Page 71: Capacitors

    It is not possible to predict a capacitor failure. Capacitor failure is usually followed by damage to the unit and an input cable 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.
  • Page 72: Replacing The Capacitor Pack (R8)

    Replacing the capacitor pack (R8) 1. Remove the front cover. Remove the profiled side plate. 2. Disconnect the discharging resistor wires. 3. Undo the fastening screws. 4. Lift the capacitor pack out. 5. Install the new capacitor pack in reverse order to the above. At the rear side (view from below) 2 pcs in...
  • Page 73: Replacing The Drive Module

    Replacing the drive module • Disconnect the input power cable from the module. • Disconnect the power supply cable and the fibre optic cables from the RMIO board and coil them on the top of the converter module. • Disconnect the busbars outside the module. •...
  • Page 74: Leds

    LEDs This table describes LEDs of the drive. Where When the LED is lit RMIO board Drive in fault state Green The power supply on the board is OK. Control panel mounting platform Drive in fault state Green The main + 24 V power supply for the control panel and the RMIO board is OK.
  • Page 75: Technical Data

    CE and other markings, and warranty policy. IEC ratings The IEC ratings for the ACS800-04 with 50 Hz and 60 Hz supplies are given below. The symbols are described below the table. ACS800-04...
  • Page 76: Symbols

    ACS800-04 Nominal ratings Light-overload use Heavy-duty use Frame Air flow Heat overload size size dissipation cont.max cont.max Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V -0140-7 2800 -0170-7 3550 -0210-7 166/203* 294...
  • Page 77: Sizing

    At altitudes from 1000 to 4000 m (3281 to 13123 ft) above sea level, the derating is 1 % for every 100 m (328 ft). For a more accurate derating, use the DriveSize PC tool. If the installation site is higher than 2000 m (6600 ft) above sea level, please contact your local ABB distributor or office for further information.
  • Page 78: Standard Gg Fuses

    Standard gG fuses ACS800-04 Input Fuse size current Manufacturer Type IEC size Three-phase supply voltage 208 V, 220 V, 230 V or 240 V -0080-2 550 000 ABB Control OFAF1H250 -0100-2 1 100 000 ABB Control OFAF2H315 -0120-2 1 100 000...
  • Page 79: Ultrarapid (Ar) Fuses

    Ultrarapid (aR) fuses ACS800-04 Input Fuse size current Manufacturer Type DIN 43620 Size Three-phase supply voltage 208 V, 220 V, 230 V or 240 V -0080-2 105 000 Bussmann 170M3819 DIN1* -0100-2 145 000 Bussmann 170M5810 DIN2* -0120-2 190 000...
  • Page 80: Cable Types

    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).
  • Page 81: Dimensions, Weights And Noise

    Dimensions, weights and noise Frame size IP 00 Weight Noise Busbars on the long side Busbars on the short side (flat) (bookshelf) 1121 1181 1564 1596 height W1 width of the basic unit with PE terminal (bookshelf) W2 width with the cable connection terminal plates on the left side only (bookshelf) (R7: width with the cable connection terminal plates on both sides is 579 mm) (R8: width with the cable connection terminal plates on both sides is 776 mm) depth without fastening brackets...
  • Page 82: Motor Connection

    Approximately 98 % at nominal power level Cooling Method Internal fan, flow direction from front to top Free space around the unit Refer to ACS800-04/04M/U4 Cabinet Installation [68360323 (English)]. Cooling air flow IEC ratings. Degrees of protection IP 00 (UL type: open chassis)
  • Page 83: Ambient Conditions

    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...
  • Page 84: Materials

    Provisions for compliance: The final assembler of the machine is responsible for installing - an emergency-stop device - a supply disconnecting device - the ACS800-04/04M/U4 into a cabinet. • EN 60529: 1991 (IEC 529) Degrees of protection provided by enclosures (IP code) •...
  • Page 85: Ce Marking

    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.
  • Page 86: Second Environment

    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.
  • Page 87: C-Tick" Marking

    “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 (1996) – Adjustable speed electrical power drive systems – Part 3: EMC product standard including specific test methods), mandated by the Trans-Tasman Electromagnetic Compatibility Scheme.
  • Page 88: Second Environment

    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.
  • Page 89: Us Tables

    US tables NEMA ratings The NEMA ratings for the ACS800-U4 and ACS800-04 with 60 Hz supplies are given below. The symbols are described below the table. For sizing, derating and 50 Hz supplies, see ratings. ACS800-U4 size Normal use Heavy-duty use...
  • Page 90: Symbols

    30 °C (86 °F). If ambient temperature is 40 °C (104 °F), I is 704 A. higher value available if output frequency is above 41 Hz ACS800-U4 types only Symbols maximum output current. Available for 10 s at start, otherwise as long as allowed by drive temperature.
  • Page 91 ACS800-U4 type Input Fuse current Manufacturer Type UL class Three-phase supply voltage 208 V, 220 V, 230 V, 240 V -0080-2 Bussmann JJS-250 -0100-2 Bussmann JJS-300 -0120-2 Bussmann JJS-400 -0140-2 Bussmann JJS-500 -0170-2 Bussmann JJS-600 -0210-2 Bussmann JJS-600 -0230-2 Bussmann...
  • Page 92: Ultrarapid (Ar) Fuses

    Ultrarapid (aR) fuses ACS800-U4 Input Fuse size current Manufacturer Type Size DIN 43653/110 Three-phase supply voltage 208 V, 220 V, 230 V, 240 V -0080-2 105 000 Bussmann 170M3169 -0100-2 145 000 Bussmann 170M5160 -0120-2 190 000 Bussmann 170M5161 -0140-2...
  • Page 93: Cable Types

    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.
  • Page 94: Dimensions And Weights

    (R8 bookshelf: depth with fastening brackets is 22.48 mm) UL/CSA markings The ACS800-04, ACS800-U4 and ACS800-04M are C-UL US listed and CSA marked. The approval is valid with rated voltages (up to 600 V). 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).
  • Page 95: Resistor Braking

    To which products this chapter applies This chapter applies to the ACS800-01/U1 (frame sizes R2 to R6), ACS800-02/U2 (frame sizes R7 and R8), ACS800-04/U4 (frame sizes R7 and R8) and ACS800-07/ U7 (frame sizes R6, R7 and R8). Availability of brake choppers and resistors for the ACS800 Frame R2 and R3 drives have a built-in brake chopper as standard equipment.
  • Page 96: Optional Brake Chopper And Resistor(S) For The Acs800-01/U1

    Optional brake chopper and resistor(s) for the ACS800-01/U1 The nominal ratings for dimensiong the brake resistors for the ACS800-01 and ACS800-U1 are given below at an ambient temperature of 40 °C (104 °F). ACS 800-01 type Braking power of...
  • Page 97 ACS 800-01 type Braking power of Brake resistor(s) ACS 800-U1 type the chopper and the drive Type brcont Rcont (kW) (ohm) (kJ) (kW) 400 V units -0003-3 SACE08RE44 -0004-3 SACE08RE44 -0005-3 SACE08RE44 -0006-3 SACE08RE44 -0009-3 SACE08RE44 -0011-3 SACE15RE22 -0016-3 SACE15RE22 -0020-3 SACE15RE22 -0025-3...
  • Page 98: Acs800-07/U7

    Optional brake chopper and resistor(s) for the ACS800-02/U2, ACS800-04/ 04M/U4 and ACS800-07/U7 The nominal ratings for dimensiong the brake resistors for the ACS800-02/U2, ACS800-04/04M/U4 and ACS800-07/U7 are given below at an ambient temperature of 40 °C (104 °F). ACS 800 type...
  • Page 99 Continuous power (heat) dissipation of the resistor when placed correctly. Energy E dissipates in 400 seconds. Rcont ACS800-Ux types only 240 kW possible if ambient temperature is below 33 °C (91 °F) 160 kW possible if ambient temperature is below 33 °C (91 °F) 630 kW possible if ambient temperature is below 33 °C (91 °F)
  • Page 100: Resistor Installation And Wiring

    Combined braking cycles for R7: Examples max 5 s or 10 s or P br10 br30 brcont No braking max 30 s min. 30 s min. 30 s max 30 s min. 30 s • After P or P braking, the drive and the chopper will withstand P continuously.
  • Page 101: Acs800-07/U7

    Note: If an external brake chopper (outside the drive module) is used, a main contactor is always required. A thermal switch (standard in ABB resistors) is required for safety reasons. The cable must be shielded and not longer than the resistor cable.
  • Page 102: Brake Circuit Commissioning

    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.
  • Page 104 ABB Oy ABB Inc. AC Drives Automation Technologies P.O. Box 184 Drives and Motors FI-00381 HELSINKI 16250 West Glendale Drive FINLAND New Berlin, WI 53151 Telephone +358 10 22 11 +358 10 22 22681 Telephone 262 785-3200 Internet http://www.abb.com 800-HELP-365...

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