Hardware Manual ACS800-07LC Drives

ACS800
Hardware Manual
ACS800-07LC Drives
ACS800 liquid-cooled single drive manuals
DRIVE HARDWARE MANUAL1) Code (EN)
ACS800-07LC Hardware Manual 3AFE68620902
SUPPLY UNIT FIRMWARE MANUAL1)

ACS800 Liquid-cooled Diode Supply Control Program Firmware 3AFE68746299
Manual
INVERTER UNIT FIRMWARE MANUALS, SUPPLEMENTS AND

GUIDES 2)
Standard Application Program Firmware Manual and 3AFE64527592,
Adaptive Program Application Guide 3AFE64527274
System Application Program Firmware Manual and 3AFE64670646,
Adaptive Application Guide 3AFE68420075
Application Program Template Firmware Manual 3AFE64616340
Master/Follower Application Guide 3AFE64590430
Pump Control Application Program Firmware Manual 3AFE68478952
Extruder Control Program Supplement 3AFE64648543
Centrifuge Control Program Supplement 3AFE64667246
Traverse Control Program Supplement 3AFE64618334
Crane Control Program Firmware Manual 3BSE11179
etc.
2)
OPTION MANUALS
Manuals for Fieldbus Adapters, I/O Extension Modules etc.
LIQUID COOLING UNIT MANUAL 3)
ACS800-1007LC Liquid-cooling Unit User's Manual 3AFE68621101
1)
Always included in the delivery
2)
Included in the delivery with appropriate program or option device
3)
Included in the delivery with the optional liquid-cooling unit
ACS800-07LC Drives
Hardware Manual
3AFE68620902 Rev B
EN
EFFECTIVE: 24.10.2006
© 2006 ABB Oy. All Rights Reserved.

5
Safety instructions
What this chapter contains

This chapter contains safety instructions you must follow when installing, operating
and servicing the drive. If ignored, physical injury or death may follow, or damage
may occur to the drive, the motor or driven equipment. Read the safety instructions
before you work on the drive.
The information is valid for ACS800-07LC single drive and ACS800 liquid-cooled
multidrive, and for the multidrive modules when equipped with similar auxiliary
devices.
Usage of warnings and notes

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

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

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

These warnings are intended for all who work on the drive, motor cable or motor.
Ignoring the instructions can cause physical injury or death, or damage the
equipment
WARNING!
• Only qualified electricians are allowed to install and maintain the drive!
• Before working on the input cubicle, isolate the whole drive from the supply. The
main disconnector of the drive does not remove the voltage from the input
busbars of 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 minutes to let the intermediate
circuit capacitors discharge before you start working on the drive, motor or motor
cable. Measure the voltage between power terminals and earth with a multimeter
(impedance at least 1 Mohm) to ensure that the drive is discharged before
beginning work.
• Apply temporary grounding before working on the unit.
• Do not work on the control cables when power is applied to the drive or to the
external control circuits. Externally supplied control circuits may carry dangerous
voltage even when the main power of the drive is switched off.
• When joining shipping splits (if any), check the cable connections at the joints
before switching on the supply voltage.
• Live parts inside the cubicle are protected against direct contact. However, pay
special attention when handling metallic shrouds.
• Do not make any insulation resistance or withstand voltage tests on the drive or
drive modules.
• Isolate the motor cables from the drive when testing the insulation resistance of or
withstand voltage of the cables or the motor.
• 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 drive DC bus carry a dangerous voltage (over 500 V).
• Depending on the external wiring, dangerous voltage (115 V, 220 V or 230 V) may
be present on the relay outputs of the drive system.
• The Prevention of Unexpected Start function does not remove the voltage from
the main and auxiliary circuits.
Safety instructions
7
WARNING!
• Use extreme caution when manoeuvring heavy inverter, supply or filter modules.
• Beware of hot surfaces. Some parts inside the drive cabinet, such as heatsinks of
power semiconductors, remain hot for a while after the 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 lead to
malfunction.
• Recommendation: Do not fasten the cabinet by riveting or welding. However, if
welding is necessary, ensure that the return wire is properly connected close to
the weld in order not to cause damage to the electronic equipment in the cabinet.
Also ensure that welding fumes are not inhaled.
Grounding
These instructions are intended for all who are responsible for the grounding of the
drive. Incorrect grounding can cause physical injury, death or equipment malfunction
and increase electromagnetic interference.
WARNING!
• Ground the drive, the motor and adjoining equipment to ensure personnel safety
in all circumstances, and to reduce electromagnetic emission and pick-up.
• Make sure that grounding conductors are adequately sized as required by safety
regulations.
• In a multiple-drive installation, connect each drive separately to protective
earth (PE).
• Do not install a drive equipped with an EMC (line) filter (option +L202) to an
ungrounded power system or a high resistance-grounded (over 30 ohms) power
system.
Note:
• Power cable shields are suitable for equipment grounding conductors only when
adequately sized to meet safety regulations.
Safety instructions
8
Use of the hand-operated winch

These instructions are intended for all who use the hand-operated winch delivered
with the drive when replacing the converter modules. Ignoring these instructions can
cause physical injury or death, or damage the equipment.
WARNING!
• Before using the winch for the first time, spool out 2 metres (6 feet) of cable, then
rewind the cable onto the drum keeping enough tension on the cable to make
sure no slack is left on the drum.
• When lowering the module, keep in mind that any slack on the winch may cause
the module to suddenly drop for several centimetres.
• After using the winch, rewind the cable onto the drum keeping enough tension on
the cable to make sure no slack is left on the drum.
Work on the liquid cooling system

These instructions are intended for all who are responsible for installation and
maintenance work of the liquid cooling system of the drive. Ignoring these
instructions can cause physical injury or damage to the equipment.
WARNING!
• Beware of hot liquid. Do not work on the liquid cooling system until the pressure is
lowered down by stopping the pumps. High-pressure warm coolant is present in
the internal cooling circuit when it is in operation.
• Before power switch-on, make sure that the internal cooling circuit is filled up with
coolant. Running the pump dry will damage it. Also the drive will not cool down.
• Units with a liquid cooling unit option (+C139, +C140, +C141): Do not open
the pump inlet or outlet valves before filling up the internal cooling circuit. The
pumps are prefilled with a water-glycol-inhibitor mixture to prevent corrosion and
the valves are closed at the factory.
• Avoid skin contact with coolant, especially antifreeze. Do not syphon them by
mouth. If such substance is swallowed or gets into the eyes, seek medical advice.
• Do not overtighten the outer union of the nuts of the liquid
hoses - leave 2 to 3 mm of thread visible. Overtightening will
break the hose. 2 mm
• Drain the unit before storing in temperatures below 0°C.

Freezing of the liquid cooling system is not allowed. If the ambient temperature is
below +5°C, add antifreeze and corrosion inhibitors to the cooling liquid.
Operation at temperatures below zero is not permitted, not even with antifreeze.
Safety instructions
9
Printed circuit boards and fibre optic cables

These instructions are intended for all who handle the circuit board and fibre optic
cables. Ignoring the following instructions can cause damage to the equipment.
WARNING! The printed circuit boards contain components sensitive to electrostatic

discharge. Wear a grounding wrist band when handling the boards. Do not touch the
boards unnecessarily.
WARNING! Handle the fibre optic cables with care. When unplugging optic cables,
always grab the connector, not the cable itself. Do not touch the ends of the fibres
with bare hands as the fibre is extremely sensitive to dirt. The minimum allowed
bend radius is 35 mm (1.38 in.).
Operation
These warnings are intended for all who plan the operation of the drive or operate
the drive. Ignoring the instructions can cause physical injury or death or damage the
equipment.
WARNING!
• 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.
• The doors of the drive must be kept locked when the drive is in operation.
• Before power switch-on, make sure that the liquid cooling circuit is filled up with
coolant. Running the pump dry will damage it. Also the drive will not cool down.
• Do not control the motor with the disconnecting device (means); instead, use the
control panel keys and , or commands via the I/O board of the drive. The
maximum allowed number of charging cycles of the DC capacitors (i.e. power-ups
by applying power) is five in ten minutes.
Note:
• If an external source for start command is selected and it is ON, the drive will start
immediately after fault reset unless the drive is configured for a pulse-start/stop
by a parameter.
• When the control location is not set to Local (L not shown in the status row of the
display), the stop key on the control panel will not stop the drive. To stop the drive
using the control panel, press the LOC/REM key and then the stop key .
Safety instructions
10
Permanent magnet motor drives

These are additional warnings concerning permanent magnet motor drives. 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.
• Prevent the start-up of the motors coupled to the same mechanical system and
ensure that no other system can rotate the motor.
• 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
11
Table of contents
ACS800 liquid-cooled single drive manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety instructions
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Usage of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Use of the hand-operated winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Work on the liquid cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Printed circuit boards and fibre optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Start-up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Table of contents
About this manual

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Common chapters for several products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Categorization according to the frame size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation and commissioning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Other manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Hardware description
Operation basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Overview – 6 or 12-pulse drive with modules 1×D4+2×R8i, no built-in main contactor or breaker (no
option +F255 or +F250) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Overview – 6-pulse drive with modules 2×D4+4×R8i and a built-in main breaker (option +F255) . 26
Swing-out frame in the supply module cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Swing-out frame in the inverter module cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Cabling direction options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Single-line circuit diagram of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Door switches and control panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Supply unit control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Connections and use of the IO in the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Connections to standard I/O terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Table of contents
12
Inverter unit control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Connections and use of the IO in the inverter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Basic code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Option codes (plus codes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Mechanical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Checking the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Moving the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
…by crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
…by fork-lift or pallet truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
…on rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Final placement of the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Installation procedure - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Fastening the cabinet to the floor (Non-marine units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Using the holes inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Fastening the unit to the floor and wall (Marine units, option +C121) . . . . . . . . . . . . . . . . . . . . . . .48
Joining the shipping splits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Preparations for the liquid pipe connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Fastening the cabinets together . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Connecting the liquid pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Connecting the PE busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Connecting the DC busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Cable duct in the floor below the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Electric welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Planning the electrical installation

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Supply disconnecting device (disconnecting means) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
EU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
US . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Motor selection and compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Permanent magnet synchronous motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Thermal overload protection of drive and cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Thermal overload protection of motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Protection against short-circuit in motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Protection against short-circuit inside the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Protection against short-circuit in the supply (AC line) cable . . . . . . . . . . . . . . . . . . . . . . . . .61
Earth fault (ground fault) protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Table of contents
13
Emergency stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Restarting after an emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Prevention of unexpected start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Typical power cable sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Arranging the external power supply for the auxiliary circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Power factor compensation capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Equipment connected to the motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Installation of safety switches, contactors, connection boxes, etc. . . . . . . . . . . . . . . . . . . . . 70
Bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Before opening an output contactor (in DTC motor control mode) . . . . . . . . . . . . . . . . . . . . 71
Relay output contacts and inductive loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Coaxial cable (for use with Advant Controllers AC 80/AC 800) . . . . . . . . . . . . . . . . . . . . . . . 72
Connection of a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
PELV and installation sites above 2000 metres (6562 feet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Electrical installation
Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Input cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Checking the compatibility with IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Input power and charging circuit connection – drives without a built-in main breaker (no option +F255)
or contactor (+F250) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Connection diagram – 6-pulse units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Connection diagram – 12-pulse units (option +A004) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Connection procedure – 6-pulse to 24-pulse units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Input power connection – drives with built-in main breaker (option +F255) or
contactor (option +F250) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Connection diagram – 6-pulse units (option +F255 or +F250) . . . . . . . . . . . . . . . . . . . . . . . 82
Connection diagram – 12-pulse units (options +A004 and +F255 or +F250) . . . . . . . . . . . . 83
Connection procedure – 6- to 24-pulse units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
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Motor connection – Frame R8i without the Common Motor Terminal cubicle (no option +H359) or
Common Motor Terminal connection (no option +H366) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Connection diagram – single inverter module feeds one motor . . . . . . . . . . . . . . . . . . . . . . .87
Connection diagram – parallel inverter modules feed one motor . . . . . . . . . . . . . . . . . . . . . .87
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Motor connection – Units with the Common Motor Terminal connection (option +H366) . . . . . . . .91
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Motor connection – Units with the Common Motor Terminal cubicle (option +H359) . . . . . . . . . . .92
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Connection of external power supply for the auxiliary circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Connection diagram, case 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Connection diagram, case 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
External control connections to the inverter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
IO connection diagram (non-US version of the Standard Application Program) . . . . . . . . . . .97
IO connection diagram (US version of the Standard Application Program) . . . . . . . . . . . . . .98
External control connections to the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Control cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Installation of optional modules and PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
PC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Installation of option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Cabling of I/O and fieldbus modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Cabling of pulse encoder interface module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Fibre optic links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Installation checklist
Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Start-up
Basic checks with no voltage connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Connecting voltage to input terminals and auxiliary circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Starting the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Checks with the supply unit running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Inverter unit application program set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
On-load checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Fault tracing
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
LEDs of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
Maintenance
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
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15
Replacing the fan of the diode supply module cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Replacing the fan in 400 mm wide incoming cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Replacing the fan in 600 mm or 1000 mm wide incoming cubicle . . . . . . . . . . . . . . . . . . . . 112
Replacing the fan in the inverter module cubicle (frame size R8i) . . . . . . . . . . . . . . . . . . . . 113
Supply module D3 and D4 replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Inverter module R8i replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Installing the winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Installing the installation stand for supply module D3 and D4 replacement . . . . . . . . . . . . . . . . . 125
Installing the installation stand for inverter module R8i replacement . . . . . . . . . . . . . . . . . . . . . . 126
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Capacitor replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
The internal cooling circuit

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Internal cooling system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Connection to a cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Connection to an ACS800-1007LC cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Connection to a custom cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
General requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Coolant temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Filling up and bleeding the internal cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Draining the internal cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Temperature limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Pressure limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Water quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Freeze protection and corrosion inhibition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Glycol concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Motor control and I/O board (RMIO) specification

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
To which board type and revisions this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
RMIO board specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Analogue inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Constant voltage output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Auxiliary power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Analogue outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
DDCS fibre optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
24 VDC power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
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16
Technical data
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Output frequency derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Auxiliary circuit current consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Type equivalence tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
Supply and inverter units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
ACS800-07LC frame sizes and power module types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Losses and cooling circuit data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
Supply unit AC and DC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Inverter unit DC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Input busbar and lead-through data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
Units without built-in main breaker or contactor (no option +F250 or +F255) . . . . . . . . . . . .150
Units with built-in main breaker (option +F255) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Units with built-in main contactor (option +F250) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Motor cable busbar and lead-through data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
Units without the Common Motor Terminal cubicle (no option +H359) . . . . . . . . . . . . . . . . .152
Units with the Common Motor Terminal (CMT) cubicle (option +H359) . . . . . . . . . . . . . . . .153
Input power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Transformer for a 12-, 18- and 24 -pulse supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
Internal cooling circuit data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
Tightening torques for power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Compliance with the EN 61800-3 (2004), category C2 . . . . . . . . . . . . . . . . . . . . . . . .158
Compliance with the Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
UL and CSA markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
UL and CSA notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Patent protection in the USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Table of contents
17
Dimensions and weights

Cubicle widths and positions in cabinet line-ups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Cubicle widths and positions in the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Cubicle widths and positions in inverter units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Cubicle widths and positions in brake units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Cubicle widths and positions in cooling units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Table of contents
18
Table of contents
19
About this manual

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

Some chapters apply to several ACS800 drive types. The types are listed in the
introduction of the chapter.
Categorization according to the frame size

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

20
Contents
The chapters of this manual are briefly described below.
Safety instructions contains safety instructions for the installation, commissioning,
operation and maintenance of the drive.
About this manual introduces this manual.
Hardware description describes the main parts of the drive.
Mechanical installation instructs how to move, place and mount the drive.
Planning the electrical installation provides advice on motor and cable selection, the
protective functions of the drive, and cable routing.
Electrical installation describes the cabling and wiring of the drive.
Motor control and I/O board (RMIO) specification shows the control board
specifications.
Installation checklist helps in checking the mechanical and electrical installation of
the drive.
Start-up guides through the drive start-up procedure.
Maintenance contains preventive maintenance instructions and instructs in supply
and inverter module replacement.
Fault tracing contains troubleshooting instructions.
Technical data contains the technical specifications of the drive, e.g. ratings, frame
sizes and technical requirements, provisions for fulfilling the requirements for CE
and other markings and warranty policy.
Dimensions and weights contains information on the dimensions of the drive.
The internal cooling circuit contains information on the drive internal cooling system.
About this manual

21
Installation and commissioning flowchart
Task See
Plan the installation. Check: ambient conditions, ratings, Technical data, page 141
required external cooling circuit arrangements, input power Planning the electrical installation, page 55
connection, compatibility of the motor, motor connection,
Option manuals (if optional equipment is included)
etc.
Select the cables.
Unpack and check the units. Delivery check, page 44

Check the type code indicated on the type designation label
against the original order.
If the drive is about to be connected to an IT (ungrounded) Contact your local ABB representative for a separate
system, check that the drive is not equipped with EMC/RFI instruction.
filtering +E202.
Check that all necessary optional modules and equipment
are present and correct.
If the converter has been non-operational for more than one Contact your local ABB representative.
year, reform the converter DC link capacitors.
Only intact units may be started up!
Check the installation site. Mechanical installation, page 41
Route the cables. Routing the cables, page 73
Mount the cabinet line-up. Mechanical installation, page 41
Check the insulation of the motor and the motor cable. Checking the insulation of the assembly, page 75
Connect the power cables. Connect the control and the Electrical installation, page 75
auxiliary control cables.
Check the installation. Installation checklist, page 103
Commission the drive. Start-up, page 105 and appropriate firmware manual
About this manual

22
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 ABB Oy, AC Drives, PO Box 184, 00381 Helsinki,
Finland.
Other manuals
See the inside of the front cover.
Terms and abbreviations

Term Definition
AIMA I/O Module Adapter (optional)
APBU PPCS Branching and Data logger Unit. Handles the communication between the inverter
control unit (RMIO board) and parallel inverter modules.
D3 Supply module frame size
D4 Supply module frame size
DDCS Serial communication protocol used in ABB drives
DSCB Diode Supply Control Board
DSU Diode Supply Unit
NAIO-03F Supply Unit Measuring Adapter. A board used in supply unit.
R8i Inverter module frame size
RAIO Analogue I/O extension module (optional)
RAPI 24 VDC back-up accumulator board for auxiliary power
RDCO DDCS Communication Option. A satellite board that can be snapped on the RMIO board
to add the no. of fibre optic channels available. In ACS800-07LC, the RDCO is installed
as standard onto supply and inverter unit RMIO boards.
RDCU Drive Control Unit. The RDCU houses the RMIO board inside a plastic casing which can
be snapped on a standard installation rail.
RDIO Digital I/O extension module (optional)
RDNA DeviceNet Adapter Module (optional)
RMBA Modbus Adapter Module (optional)
RMIO Motor Control and I/O Board. In ACS800-07LC, there is one RMIO board for the supply
unit and one for the inverter unit.
RPBA Profibus Adapter Module (optional)
RTAC Pulse Encoder Adapter Module (optional)
About this manual

23

This chapter describes the construction of the drive.
Operation basics
The ACS800-07LC is a cabinet-mounted liquid-cooled drive for controlling AC
motors.
The drive consists of several cubicles that contain: the input and motor cable
terminals, diode supply module(s), inverter modules, and various optional
equipment. The actual arrangement of the cubicles varies depending on the drive
type and selected options. See the chapter Dimensions and weights for the different
line-up variations.
24
Overview – 6 or 12-pulse drive with modules 1×D4+2×R8i, no built-in main

contactor or breaker (no option +F255 or +F250)
Supply module cubicle (1×D4) contains:
No. Description
1. Supply unit control panel
2. Drive operating switches
3. Input power cable terminals and diode supply module input fuses (behind the fan)
4. PE terminal (cabinet grounding busbar behind the coolant pipe)
5. Terminal blocks for the connections of main breaker control and supervision circuits, and
connection point for the supply of the charging circuit (not needed in half-controlled supply
units, i.e. when there are no charging resistors).
6. Swing-out frame with supply unit control electronics. See Swing-out frame in the supply
module cubicle on page 28.
7. Diode supply module (behind the swing-out frame)
8. Diode supply module output fuses
Inverter module cubicle (2×R8i) contains:

No. Description
9. Inverter unit control panel
10. Inverter module input DC fuses
11. Inverter modules 1 and 2 (behind the swing out frame)
12. Swing-out frame with inverter unit control electronics, I/O terminal blocks and communication
options. See Swing-out frame in the inverter module cubicle on page 29.
13. Motor cable terminals (busbars behind the fan)
14. Motor grounding terminal (common cabinet grounding busbar behind the coolant pipe)
15. Terminal block for connection of prevention of unexpected start circuit (option +Q950)
16. Terminal block for connection of motor temperature supervision/protection circuit (option
+L506, +L506 or +L513)
25
Doors closed Doors open

Supply module Inverter module cubicle
cubicle
1 2 9
10
8
7
11
6 12
3 13
5
15 16
4
14
26
Overview – 6-pulse drive with modules 2×D4+4×R8i and a built-in main

breaker (option +F255)
Supply module cubicles (2×D4) and main braker cubicle contain:
No. Description
1. Supply unit control panel
2. Drive operating switches
3. Main breaker (option +F255)
4. Earthing switch (option +F259)
5. Input power cable terminals (busbars)
6. PE terminal (cabinet grounding busbar behind the coolant pipe)
7. Swing-out frame with supply unit control electronics. See Swing-out frame in the supply
module cubicle on page 28.
8. Diode supply module input fuses (behind the fan)
9. Diode supply module 1 and 2 (module 1 is behind the swing-out frame)
10. Diode supply module output fuses
Inverter module cubicles (2×2×R8i) contain:

No. Description
11. Inverter unit control panel
12. Inverter module input fuses
13. Inverter modules 1 and 2 (behind the swing out frame)
14. Inverter modules 3 and 4
15. Swing-out frame with inverter unit control electronics, I/O terminal blocks and communication
options. See Swing-out frame in the inverter module cubicle on page 29.
16. Motor cable terminals (busbars behind the fan)
17. Motor grounding terminal (cabinet grounding busbar behind the coolant pipe)
18. Terminal block for connection of prevention of unexpected start-up circuit (option +Q950)
19. Terminal block for connection of motor temperature supervision/protection circuit (option
+L506, +L506 or +L513)
27
Doors closed
4 1 2 11
Doors open, shrouds removed
12 12
10 10
9
9
13
14
15
7
8 8
5 16 16
18 19
6 17 17
28
Swing-out frame in the supply module cubicle

The swing-out frame inside the supply module cubicle provides space for the supply
control unit (RDCU) and DSCB board, NAIO-03F adapter, terminal blocks, breakers
for the auxiliary circuits, etc. Note that the terminal blocks for the customer
connections are not on the swing out frame but on side assembly plates at the lower
part of the cubicle.
The frame can be opened by removing the mounting screws and moving the swing-
out frame aside. Depending on selected options, actual equipment may differ
somewhat from what is depicted below.
No. Description
1. Supply control unit [RDCU] including the

9 10 control board [RMIO]
2. RDCO DDCS Adapter
3. DSCB board [DSCB]
7 8 4. Supply unit measuring adapter [NAIO-03F]
5. 24 VDC power supply
6. 24 VDC back-up accumulator
7. Circuit breakers (auxiliary circuits)
8. Terminal block X1
4 5 6
9. Earth (ground) fault monitoring unit (optional)
10. Safety relay and time relays of supply unit

control circuit
3 1
29
Swing-out frame in the inverter module cubicle

The swing-out frame inside the inverter module cubicle provides space for the
inverter control unit (RDCU), branching unit (APBU – only if the drive includes
parallel inverter modules), I/O signal terminal blocks and auxiliary circuit terminal
blocks, breakers and relays.
The frame can be opened by removing the mounting screws and moving the swing-
out frame aside. Depending on selected options, actual equipment may differ from
what is depicted below.
7 8 9 No. Description
1. Inverter control unit [RDCU] including the

control board [RMIO]
2. RDCO DDCS Adapter

11 3. Branching unit (in case of several parallel
inverter modules) [APBU]
4
4. 24 VDC power supply
10 5. 24 VDC back-up accumulator (Auxiliary Power
5 Interface Board [RAPI])
6. Terminal block for external IO connections,

hard wired to RDCU terminals (option +L504)
7. Terminal blocks for auxiliary voltage distribution

2
8. Auxiliary circuit breakers (optional)
6 1 3
9. Control relays (optional)
10. Relays for motor temperature supervision
11. I/O Module Adapter, AIMA (optional)
Layout of the swing-out frame for inverter cubicle with modules (2×R8i or 3×R8i).
Note that the layout differs slightly in the narrower 1×R8i cubicle.
30
Cabling direction options

All drives are equipped with bottom cable entry and exit as standard. However, top
cable entry and exit are available if the drive is equipped with the main breaker or
contactor cubicle (option +F255 or +F250) and one of the following output options:
• common motor terminals cubicle (option +H359)
• sine output filter cubicle (option +E206)
• output contactor cubicle (option +F269).
Note: Not all option combinations given above are available for all drive types.
Check the availability with ABB.
Diode supply module Inverter modules DC bus
Brake choppers3)
Brake resistors4)
M M M
M
Single-line circuit diagram of the drive
Main breakers1)
U<
4)
Main supply
U<
(12-pulse) M
3~
Charging circuit Notes:

The diagram represents a frame 1×D4 + 2×R8i drive with brake
chopper and resistor units.
1)
Main breaker (two for a 12-pulse connection) is provided by
Control circuitry customer. The breaker is also available as optional equipment.
2) Auxiliary voltage supply is provided by customer. An auxiliary
voltage transformer is also available as optional equipment.
3)
Chopper is available as optional equipment.
Auxiliary circuit main 4) Resistor is to be provided by customer.
switch
Auxiliary voltage
230 (115) VAC2)
31
32
Door switches and control panels

Door switches are placed on the door of the supply module cubicle.
2 3 1 4
1. Operating switch Emergency stop 0 1 START

Operating switch:
EMERGENCY
and emergency stop button (optional) START – closes main breaker,
controls starts supply module(s)
STOP
1 – keeps drive in operation

Emergency stop 0 – opens main breaker, stops
reset button supply unit
(optional) RESET
2. Earthing/ Temporary grounding of main AC input busbars (option code +F259)

Grounding switch
3. Control panel 1 Diode supply unit control panel
4. Control panel 2 Inverter unit control panel
33
Supply unit control interfaces

The supply unit is controlled by an RDCU control unit located in the swing-out frame
of the supply module cubicle. The RDCU connects to supply modules via the DSCB
board.
A control panel is installed on the door of the supply module cubicle. The panel is the
user interface for the diagnostics (actual signals), parameter settings and local
control (start, stop, reset). See the ACS800 Diode Supply Control Program Firmware
Manual (code: 3AFE68746299 [English]) for further information.
Typically, the user controls the supply unit operation (charging, main breaker on/off,
supply modules) with the door switches. The switches are a part of the control
circuitry that connects to supply unit via the IO of the RDCU control unit. The
composition of the control circuitry vary depending on the drive options.
Control unit (RDCU)
Control
Control panel
board (RMIO)
Communication module 1: IO extension (RAIO, RDIO)
Slot 1 or fieldbus adapter (e.g. RMBA, RDNA, RPBA).
Optional device. 1)
Communication module 2: IO extension (RDIO, RAIO).

X20…27 Slot 2 Optional device.
0 1 START Communication module 3: DDCS adapter (RDCO-0x).

Slot 3
EMERGENCY
Installed as standard.
STOP
RESET
Supply Unit Inverter unit. PC, IO modules,
Supply unit control circuitry: Measuring Connected by fieldbus adapter.
door switches, main breaker control, Adapter (NAIO- default. See Optional
etc. 03F). Installed Inverter unit device.
as standard. control
2) interfaces on
DSCB page 37.
2)
= ~ To motor
Input power
~ =
Supply module(s) Inverter module(s)
1)
RDIO Digital IO Extension Module is installed to option Slot 1 as standard in units with parallel supply modules.
The control program receives the ready acknowledgement signals of each module through the RDIO inputs.
For details about the interconnections of the boards, see ACS800 Liquid-cooled Supply Control Program Firmware
Manual (3AFE68746299 [English]) and the circuit diagrams delivered with the drive.
34
Connections and use of the IO in the supply unit

The table and the figure below describe the connections and use of the IO in the
supply unit. The use of IO is fixed in the supply unit control program and the wiring to
RMIO terminals are made accordingly at the factory. The settings of the supply
control program and the connections of the supply unit IO must not be changed by
the user.
IO Name Use in the control program Connected device / Purpose
RDCU standard IO channel
AI1 VDC MEASURING Diode supply module output voltage value DSCB board voltage output
A12 I SUM TOT Current sum values in total (considering DSCB board current output
measurements from all diode bridges)
AI3 I SUM MAX Maximum current sum (considering DSCB board current output
measurements from all diode bridges)
DI1 ALARM / FAULT Overtemperature supervision: 1->0: Alarm. 0: Supply module and cabinet temperature
Fault (after preset time delay). sensors (in series)
DI2 ON / OFF Supply module on/off control. 0->1: On. Operating switch
0: Stop.
DI3 ACK MAIN Main breaker supervision. 1: closed (enables Main breaker auxiliary contact
CONTACTOR supply unit start)
DI4 EARTH FAULT Earth fault supervision. Can be activated or Insulation monitoring device (optional IRDH
inactivated by parameter. 1: No fault. unit by Bender).
DI5 ALARM / FAULT Supervision of cooling unit. Can be activated Cooling unit monitoring circuit. Not in use but
or inactivated by parameter. 1->0: Alarm. hard-wired to +24 VDC of RDCU when no
0: Fault (after preset time delay). optional cooling unit is in use.
DI6 RESET Diode supply module reset. 1: Reset. Not connected as default. Fault reset can be
given from control panel.
DIIL Not in use. Not in use.
R01 CHARGING / On/off control of charging contactor. 1: On. Charging circuit control relay
ENABLE RECT
R02 LCU ON / OFF Liquid cooling unit on/off control. 1: On. Cooling unit control relay. Not connected
when no optional cooling unit is in use
R03 MAIN Main breaker control. 1: On. Breaker control circuit
CONTACTOR
CONTROL
IO extension modules
AI8 IM1TOT Current sum from diode bridge no. 1, if one DSCB board via NAIO-03F module AI1
module. Current sums from diode bridges
no. 1 in total, if two or three modules.
AI9 IM2TOT Current sum from diode bridge no. 2, if one DSCB board via NAIO-03F module AI2
module. Current sums from diode bridges
no. 1 in total, if two or three modules.
35
Connections to standard I/O terminals

Terminal block size: X20
2
cables 0.3 to 3.3 mm (22 to 12 AWG) 1 VREF- Reference voltage -10 VDC, 1 kohm < RL < 10
2 AGND kohm
Tightening torque:
X21
0.2 to 0.4 Nm (0.2 to 0.3 lb.ft)
1 VREF+ Reference voltage 10 VDC, 1 kohm < R L < 10
2 AGND kohm
Control circuitry 3 AI1+ VDC MEASURING. 0(2)…10 V, Rin > 200 kohm
DSCB board 4 AI1-
Operating switch
5 AI2+ I SUM TOT. 0(4)…20 mA, R in = 100 ohm
1 3
6 AI2-
7 AI3+ I SUM MAX . 0(4)…20 mA, Rin = 100 ohm
2 4
8 AI3-
0
1 9 AO1+ Not in use. 0(4)…20 mA, RL < 700 ohm
START
10 AO1-
Main breaker 11 AO2+ Not in use. 0(4)…20 mA, RL < 700 ohm
12 AO2-
X22
1 DI1 ALARM / FAULT
2 DI2 ON / OFF
Charging contactor
3 DI3 ACK MAIN CONTACTOR
4 DI4 EARTH FAULT
5 DI5 ALARM / FAULT
6 DI6 RESET
7 +24V +24 VDC max. 100 mA
For details, see the delivery specific 8 +24V
circuit diagrams of the cabinet-installed 9 DGND1 Digital ground
unit. The diagrams show:
10 DGND2 Digital ground
- supply unit on/off control
11 DIIL Not in use
- main breaker supervision and on/off
control X23
- charging contactor on/off control 1 +24V Auxiliary voltage output, non-isolated, 24 VDC
2 GND 250 mA
- optional auxiliary circuit wiring.
X25
WARNING! Never force the main 1 RO1 Charging contactor control: Open (0) /
breaker closed before charging has 2 RO1 close (1)
been completed. Starting sequence, i.e. 3 RO1
charging, acknowledgements, main
X26
contactor control and the supply unit
start, follows a certain order. Never 1 RO2 LCU control: Off (0) / on (1)
change the order by by-passing signals 2 RO2
(using jumpers), etc. That will cause a 3 RO2
malfunction that may damage the unit. X27
1 RO3 Main breaker control: open (0) /
2 RO3 close (1)
3 RO3
36
Inverter unit control interfaces

The inverter unit is controlled by an RDCU control unit located in the swing-out
frame. The RDCU is connected to the inverter modules by a fibre optic link. In the
modules, the optic link connects to the terminals which are accessible through a hole
on the front panel of the module. In case of parallel-connected modules, the fibre
optic link from the RDCU is distributed through an optical branching unit.
A control panel is installed on the door of the inverter module cubicle. The panel is
the user interface of the inverters, providing the essential controls such as start/stop/
direction/reset/reference, and the parameter settings for the drive application
program. See the appropriate inverter application program Firmware Manual for
further information.
Control unit (RDCU)
Control panel Control

board (RMIO)
Communication module 1: IO extension (RAIO, RDIO),
pulse encoder interface (RTAC), or fieldbus adapter
(e.g. RMBA, RDNA, RPBA). Optional device.
Communication module 2: IO extension (RAIO, RDIO)

or pulse encoder interface (RTAC). Optional device.
Communication module 3: DDCS adapter (RDCO-0x).

Installed as standard.
External control via analogue/
digital inputs and outputs
Supply unit. PC, IO modules, AIMA external

Connected by default. fieldbus adapter. interface.
See Supply unit control Optional Optional
interfaces on page 33. device. device
= ~
To motor
Input power
~ =
Supply module(s) Inverter module(s)
Connections and use of the IO in the inverter unit

The default use of the IO channels depends on the application program which is
loaded on the control board. See chapter Electrical installation, page 97 for the
default IO use in the ACS800 Standard Application Program, and the appropriate
Firmware Manual for other inverter application programs.
37
Type code
The type code of the drive is indicated on the type designation label, attached on the
door of the drive (inside). The type code contains a summary of the configuration of
the drive. The first digits from left express the basic configuration e.g.
ACS800-07LC-0560-7. The optional selections are given thereafter, separated by
plus signs, e.g. +G304. The selections are described below.
Note: The information below is for quick reference only and does not contain all
conditions and details. For more information, contact the local ABB representatives.
Basic code
Digit Name/Description Alternatives
1…6 Product series ACS800
8…11 Product type 07LC – cabinet-installed liquid-cooled drive.*
13…16 Size 0390...6620
18 Voltage rating 4 – Voltage range 380…415 VAC
5 – Voltage range 440…500 VAC
7 – Voltage range 525…690 V
* When no options are selected, the following features are included as standard: 6-pulse supply
connection, +B054 (IP42, UL type 1, NEMA 1), +G320 (230 VAC), +A012 (Supply frequency 50 Hz),
+J400 (CDP312R control panel),+E210 (EMC 2nd environment), +E205 (du/dt limitation at drive
output), +E208 (common mode filters), +N664 (Standard Application Program), +H367 (control cabling
bottom entry/exit), +H350 (bottom power cabling entry), +H352 (Bottom power cabling exit), +G315 (tin
plated copper DC-busbars), coated circuit boards, +R700 (set of English manuals), cable lead through
entry, IEC approved components, RDCO-03. Note: These option codes are not shown on the
nameplate.
Option codes (plus codes)

Code Description
Supply connection
A004 12-pulse supply connection
A013 60 Hz supply connection
Degree of protection
B055 IP54 (UL type 12)
Construction
C121 Marine construction
C129 UL listed
C134 CSA approved
Liquid cooling unit 1, nominal cooling capacity 70 kW
C140 Single pump cooling unit (capacity 70kW)
C142 Bottom pipe connection
C145 ANSI flanges
Z1140 380-415 V/50 Hz external supply voltage (pump)
C147 3-way valve, outside cabinet
38
Code Description
Liquid cooling unit 2, nominal cooling capacity 195 kW,
C141 Redundant pump cooling unit (capacity 195kW)
C139 Stand-alone version
C142 Bottom pipe connection
C144 Pipe connection on left (not with C139)
C145 ANSI flanges
C146 Sea water heat exchanger (requires C139)
C147 3-way valve, outside cabinet
Resistor braking
D150 Braking chopper (1 to 6 pcs)
D151 Braking resistor in separate cabinet
Filters
E202 EMC/RFI-filter, 1st environment, restricted (A-limits, earthed network) up to 1000A
E206 Sine output filter
Line options
F250+ Line contactor and switch fuse
F254
F255 Air circuit breaker
F259 Earthing switch (requires air circuit breaker or line contactor, not available with C129)
F269 Inverter output contactors (not available with H366, H359, E206)
F271 Output earthing terminals (requires common motor terminal cubicle, add H366)
Control voltage
G304 115 VAC control voltage
G344 Auxiliary transformer
G307 Terminals for external control voltage 230VAC or 115VAC (UPS)
Cabinet options
G300 Cabinet heater (External supply)
G313 Output for motor heater (External supply)
G317 Busbar supply conductors (requires F255 or F250)
G330 Halogen free wiring and materials
Electrical options
Q954 Earth fault monitoring, IT
Q953 Earth fault monitoring, TN
G335 A-meter in one phase
3G335 A-meter in three phases
G332 Electrical disconnect push button on the door (black)
G334 V-meter with selector
G336 Arc monitoring (Rea) (Specify configuration separately)
G337 Arc monitoring with current sensing unit
Cabling
H351 Top entry
H353 Top exit
H365 Cable gland plates (Brass 6mm, undrilled)
H364 Cable gland plates (Aluminium 3mm, undrilled
H358 Cable gland plates (Steel 3mm, undrilled)
H366 Common motor terminal connection (2× and 3× R8iLC)
H359 Common motor terminal cubicle
Fieldbus
K451 DeviceNet adapter
K452 LONWorks adapter
K454 Profibus-DP adapter
K458 Modbus adapter
K462 ControlNet
K453 Interbus-S
K455 Modbus Plus
K456 AF100
K457 CANOpen
39
Code Description
I/O options
L500 Analogue I/O extension
L501 Digital I/O extension
L502 Pulse encoder interface
L509 DDCS communication 2
L508 DDCS communication 1
L504 Additional I/O-terminal block
L505 Thermistor relay (1 or 2 pcs)
L506 Pt100 relay (3, 5 or 8 pcs)
L513 ATEX certified thermal protection with PTC
Starter for auxiliary Motor fan
M602 2,5...4 A
M603 4...6,3 A
M604 6,3...10 A
M605 10...16 A
M606 16...25 A
Software
N650 Pump and fan control (PFC)
N651 Master/follower
N652 Crane control
N653 Application program template
N654 Spinning control
N666 Extruder control
N668 Traverse control
N669 Centrifuge control
N671 System application
N682 Multi block programming
Specialities
P902 Customised (described in technical appendix)
P904 Extended warranty
P913 Special colour (Described in Technical appendix)
Safety features
Q950 Prevention of unexpected start-up
Q951 Emergency stop, stop category 0
Q952 Emergency stop, stop category 1
G331 Emergency stop push button on the door (red)
Q959 Supply transformer breaker disconnect push button (red) on the door
Documentation language
R700 English
R701 German
R702 Italian
R703 Dutch
R704 Danish
R705 Swedish
R706 Finnish
R707 French
R708 Spanish
R709 Portuguese (in Portugal)
R711 Russian
40
41

This chapter describes the mechanical installation procedure of the liquid-cooled
and cabinet-installed ACS800 drive. The information is valid for ACS800-07LC
single drive and ACS800 liquid-cooled multidrive.
Checking the installation site

See Ambient conditions on page 155 for allowable operating conditions, and
Dimensions and weight on page 145 for requirements for free space around the unit.
The unit must be installed in an upright vertical position.
The floor that the unit is installed on must be of non-flammable material, as smooth
as possible, and strong enough to support the weight of the unit. The floor flatness
must be checked with a spirit level before the installation of the cabinets into their
final position. The maximum allowed deviation from the surface level is 5 mm in
every 3 metres. The installation site should be levelled, if necessary, as the cabinet
is not equipped with adjustable feet.
The wall behind the unit must be of non-flammable material.
Note: Wide cabinet line-ups are delivered as “shipping splits”.
Required tools
The tools required for moving the unit to its final position, fastening it to the floor and
tightening the connections are listed below.
• crane, fork-lift or pallet truck (check load capacity!); iron bar, jack and rollers
• Pozidrive and Torx (2.5–6 mm) screwdrivers for the tightening of the frame
screws
• torque wrench
• set of wrenches or sockets for joining shipping splits.
42
Moving the unit
…by crane
Use the steel lifting bars attached to the top of the cabinet. Insert
the lifting ropes or slings into the holes of the lifting bars.
The lifting bars can be removed (not mandatory) once the cabinet
is in its final position. If the lifting bars are removed, the bolts
must be refastened to retain the degree of protection of the
cabinet.
IP54 units (only with the air-cooled cubicles)

Allowed minimum height of lifting ropes or slings
for IP54 units which have fan on the roof is
2 metres.
…by fork-lift or pallet truck
The centre of gravity is high. Be therefore careful when

transporting the unit. Avoid tilting the cabinets.
The units are to be moved only in the upright position.
If using a pallet truck, check its load capacity before
attempting to move the unit.
43
…on rollers
(Not allowed with Marine versions)
Remove the wooden bottom frame which is part

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

Move the cabinet into its final position with an iron bar
and a wooden piece at the bottom edge of the cabinet.
Place the wooden piece properly not to damage the
cabinet frame!
44
Before installation
Delivery check
The drive delivery contains:
• drive cabinet line-up
• optional modules (if ordered) installed into the control rack at the factory
• winch for the supply and inverter module replacement
• appropriate drive manuals and optional module manuals
• delivery documents.
Check that there are no signs of damage. Before attempting installation and
operation, check the information on the type designation label of the drive to verify
that the delivery is of the correct type. The label includes input and output ratings,
markings, a type code and a serial number, which allow individual recognition of
each unit. For the type code key, see Type code on page 37. 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 of ACS800-07 LC drive is located on the supply unit door.
In ACS800 multidrive, each unit has a label of its’ own.
Example of a type designation label (ACS800-07LC)
Each power module (i.e. supply and inverter module) is also individually labelled.
45
Installation procedure - overview

1 This section contains a brief installation
procedure. See detailed instructions on each step
in the following few pages.
(1) The cabinet can be installed with its back
against a wall, or back-to-back with another unit.
1a 1a Fasten the unit (or first shipping split) to the floor.
See Fastening the cabinet to the floor (Non-
marine units) on page 46.
With marine versions, fasten the unit (or first
shipping split) to the floor and wall/roof as
described in Fastening the unit to the floor and
wall (Marine units, option +C121) on page 48.
Note: A clearance of 400 mm minimum above the
basic roof level of the cabinet is required to
Top clearances pressure release lids (open at arc fault).
> 320 mm (12.3”) for units Note: Leave some space at the side where the
with fan on roof (option
+E206) cabinet outmost hinges are to allow the doors to
open sufficiently (1a) (doors must open 120° to
> 400 mm (15.75”)
allow supply and inverter module replacement).
Note: Any height adjustment must be done before
fastening the units or shipping splits together.
Height adjustment can be done by using metal
2 shims between the bottom frame and floor.
(2) Remove the lifting bars. Use the original bolts
to block any unused holes. In marine units, use
the holes for fastening the cabinet from top.
(3) Slide Axilock connectors onto the liquid pipe
ends. One connector per pipe.
3
(4) If the line-up consists of shipping splits, fasten
the first split to the second, see Joining the
shipping splits on page 49. Each shipping split
includes a joining cubicle where the busbars
connect to the next split.
(5) Fasten the second shipping split to the floor.
(6) Join the DC busbars (a) and the PE
4 busbars (b), liquid pipes and the loose wire ends
in the joining cubicle, see Connecting the
DC busbars on page 51 and Connecting the liquid
pipes on page 50.
5 (7) Repeat steps (2) to (6) for the remaining
shipping splits.
6a
6b
46
Fastening the cabinet to the floor (Non-marine units)

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

Width
(mm)
Cabinet frame
300 150 (5.9”)
400 250 (9.85”)
Cabinet frame 500 350 (13.78”)
600 450 (17.72”)
Above view 700 550 (21.65”)

800 650 (25.6”)
L-bracket
M16 screw
Cabinet top
Fastening the cabinet at the top when

floor mounting from back is not
possible (side view)
47
Using the holes inside the cabinet

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

cabinet (arrowed)
L-bracket
M16 screw
25 mm (0.985”)
Cabinet top
Fastening the cabinet at the top

when floor mounting from back is
not possible (side view)
Distances between fastening holes Added width:

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

400 250 (9.85”) ≈ 0.5 ≈1
(0.02”) (0.04”)
600 450 (17.7”)
700 550 (21.65”)
800 650 (25.6”)
48
Fastening the unit to the floor and wall (Marine units, option +C121)
The unit must be fastened to the floor and roof (wall) as follows:
Bolt the unit to the floor through the holes in

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

2
for installation, clamp the rear ends of the flat
bars as shown in figure (2).
Remove the lifting bars and fasten the top of

3
the cabinet to the rear wall and/or roof using
brackets.
Use M10 or M12 screws; welding is not

recommended (see Electric welding on
page 53 below).
2 3
L-bracket
Back panel of cabinet
Clamps (not
included in M16 bolt
delivery)
Flat bars at base of cabinet
Cabinet
Clamping the cabinet to the Fastening the cabinet at the top with
floor at the back brackets (side view), example
49
Joining the shipping splits
Preparations for the liquid pipe connections

Slide Axilock connectors onto the liquid pipes (when the cabinets are pushed
together the pipe ends come too close to each other and the connectors cannot be
installed any more).
Fastening the cabinets together

Two shipping splits are joined in a joining cubicle. Special M6 screws for fastening
the shipping splits together are enclosed in a plastic bag inside the cabinet. The
threaded bushings are already mounted on the post.
Fasten the front post and the rear post of the joining section with 7 screws to the
posts of the next cubicle.
7× 7×
Maximum tightening torque:
5 Nm (3 ft.-lbs)
50
Connecting the liquid pipes

Connect the cooling liquid pipes, the PE busbars and DC busbars as instructed
below. All necessary materials are located in the joining cubicle.
Ensure the Axilock connectors are slid on pipe ends.
1. Position the liquid pipe ends against each other.
2. Centre the Axilock connector onto the pipe ends.
3. Tighten the connector bolts to a torque of 20 Nm (15 lbf, ft).
1 2
Axial gap: 5 to 15 mm
(0.2” to 0.6”)
Angular error: max 2°

(any direction)
Parallel misalignment:
max 3 mm (0.2”)
Connecting the PE busbars

Connect the PE busbars as shown below.
M10 bolt
Tightening torque:
35–40 Nm (25–30 ft.-lbs.)
Strength class: 8.8
Plain washer
Spring washer
Plain washer
51
Connecting the DC busbars

Main DC busbars are connected from front. All necessary materials are located in
the joining cubicle.
1. Remove the metal plate covering the busbars in the joining cubicle.
2. Unscrew the bolts of the joint pieces.
3. Connect the busbars with the joint pieces (see figure below).
4. Refit the covering plate.
a
a = joint piece
a
a
Tighten the bolts to

55–70 Nm (40–50 ft.-lbs.)
Strength class: 8.8
Plain washer with electroplated zinc

coating and yellow chromate passivation
Side views of busbar connection
Spring washer with mechanically sprayed

zinc coating
Nut
a a
WARNING! Do not place the spring washer against the joint piece. Use the plain
washer (with electroplated zinc coating and blue passivation) instead. An
unpassivated zinc-coated spring washer positioned directly against the joint piece
would cause corrosion.
52
Miscellaneous
Cable duct in the floor below the cabinet

A cable duct can be constructed below the middle part of the cabinet. The duct width
may not exceed 450 mm. The cabinet weight lies on the 100 mm wide section in
front and 50 mm wide section on the back which the floor must carry.
Viewed from above Side view
Front
50 mm 100 mm
Front
This area can be used for a Minimum widths

cable duct for the floor support
Prevent the cooling air flow from

the cable duct to the cabinet by
bottom plates. To ensure the
degree of protection for the cabinet
use the original bottom plates
delivered with the unit. With user- Cables
defined cable entries, take care of
the degree of protection, fire
protection and EMC compliance.
53
Electric welding
It is not recommended to fasten the cabinet by welding.
Cabinets without flat bars at the base
• Connect the return conductor of the welding equipment to the cabinet frame at
the bottom within 0.5 metres of the welding point.
Cabinets with flat bars at the base
• Weld only the flat bar under the cabinet, never the cabinet frame itself.
• Clamp the welding electrode onto the flat bar about to be welded or to the next flat
bar of the cabinet (within 0.5 metres of the welding point).
WARNING! If the welding return wire is connected improperly, the welding circuit
may damage electronic circuits in the cabinet. The thickness of the zinc coating of
the cabinet frame is 100 to 200 micrometres; on the flat bars the coating is
approximately 20 micrometres. Ensure that the welding fumes are not inhaled.
54
55

This chapter contains the instructions for selecting the motor, cables, protections,
cable routing, etc. The information is valid for ACS800-07LC single drive and
ACS800 liquid-cooled multidrive, and for the multidrive modules when equipped with
similar auxiliary devices.
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.
Supply disconnecting device (disconnecting means)

Supply disconnecting device is optionally available for the cabinet-installed drives
(ACS800-07 liquid-cooled, multidrive). The drives with options +F250 (main
contactor) and +F255 (main breaker) have the disconnecting device as standard.
If the drive does not have the disconnecting device, install a hand-operated device
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.
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.

56
Motor selection and compatibility

1. Select the motor according to the rating tables in chapter Technical Data. Use
DriveSize PC tool if the default load cycles are not applicable.
2. Check that the motor ratings lie within the allowed ranges of the drive control
program:
• motor nominal voltage is 1/2 ... 2 · UN of the drive
• motor nominal current is 1/6... 2 · I2hd of the drive in DTC control and
0 ... 2 · I2hd in scalar control. The control mode is selected by a drive parameter.
3. Check that the motor voltage rating meets the application requirements:
If the drive is equipped with … … and … … then the motor voltage
rating should be …
diode supply unit1) no frequent or long-term resistor UN

braking is used
frequent or long-term resistor UACeq1

breaking is used
IGBT supply unit2) DC link voltage is not increased from UN

nominal (parameter settings)
DC link voltage is increased from UACeq2

nominal (parameter settings)
1)
Drives equipped with ACS800-304LC diode supply modules, i.e. ACS800-07LC, and ACS800 liquid-
cooled multidrive with supply unit ACS800-307LC, -507LC, -1107LC or -1207LC.
2)
Drives equipped with ACS800-104LC IGBT supply modules, i.e. ACS800-77, and ACS800 multidrive with
supply unit ACS800-207LC.
UN = Rated input voltage of drive
UACeq1 = UDC / 1.35
UACeq2 = UDC / 1.41
UACeq = Equivalent AC power source voltage of drive in VAC
UDC = Maximum DC link voltage of drive in VDC. For resistor braking: UDC = 1.21 × 1.35 × UN. For IGBT
supply unit: See the parameter value (factory default value = 1.41 × UN ).
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 on page 57 for the required
motor insulation system and drive filtering.
Example 1: When the supply voltage is 440 V and the drive has a diode supply
and operates in motor mode only, the maximum peak voltage at 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.

57
Protecting the motor insulation and bearings

The output of the drive comprises – regardless of output frequency – pulses of
approximately 1.35 times the equivalent mains network voltage with a very short rise
time. This is the case with all drives employing modern IGBT inverter technology.
The voltage of the pulses can be almost double at the motor terminals, depending on
the attenuation and reflection properties of the motor cable and the terminals. This in
turn can cause additional stress on the motor and motor cable insulation.
Modern variable speed drives with their fast rising voltage pulses and high switching
frequencies can cause current pulses that flow through the motor bearings, which
can gradually erode the bearing races and rolling elements.
The stress on motor insulation can be avoided by using optional ABB du/dt filters.
du/dt filters also reduce bearing currents.
To avoid damage to motor bearings, the cables must be selected and installed
according to the instructions given in this manual. In addition, insulated N-end (non-
driven end) bearings and output filters from ABB must be used according to the
following table. Two types of filters are used individually or in combinations:
• du/dt filtering (protects motor insulation system and reduces bearing currents).
• common mode filtering (CMF) (mainly reduces bearing currents).
Requirements table
The following table shows how to select the motor insulation system and when an
optional ABB du/dt filter, insulated N-end (non-driven end) motor bearings and ABB
common mode filters are required. The motor manufacturer should be consulted
regarding the construction of the motor insulation and additional requirements for
explosion-safe (EX) motors. Failure of the motor to fulfil the following requirements
or improper installation may shorten motor life or damage the motor bearings.
Motor type Nominal mains Requirement for
voltage (AC line
Motor insulation ABB du/dt filter, insulated N-end bearing and ABB common mode
voltage)
system filter
Manufacturer
PN < 100 kW 100 kW < PN < 350 kW PN > 350 kW

and or or
frame size < IEC 315 frame size > IEC 315 frame size > IEC 400
PN < 134 HP 134 HP < PN < 469 HP PN > 469 HP
and frame size or frame size or frame size
< NEMA 500 > NEMA 500 > NEMA 580
A Random- UN < 500 V Standard - +N + N + CMF
B wound M2_
500 V < UN < 600 V Standard + du/dt + du/dt + N + du/dt + N + CMF
B and M3_
or
Reinforced - +N + N + CMF
600 V < UN < 690 V Reinforced + du/dt + du/dt + N + du/dt + N + CMF
Form-wound 380 V < UN < 690 V Standard n.a. + N + CMF PN < 500 kW:
HX_ and AM_ + N + CMF
PN > 500 kW:
+ N + CMF + du/dt
Old* form- 380 V < UN < 690 V Check with the + du/dt with voltages over 500 V + N + CMF
wound HX_ motor
and modular manufacturer.

58

voltage (AC line
voltage) system filter
Manufacturer
PN < 100 kW 100 kW < PN < 350 kW P N > 350 kW

and or or
frame size < IEC 315 frame size > IEC 315 frame size > IEC 400
PN < 134 HP 134 HP < PN < 469 HP PN > 469 HP
and frame size or frame size or frame size
< NEMA 500 > NEMA 500 > NEMA 580
Random- 0 V < UN < 500 V Enamelled wire + N + CMF
wound HX_ with fibre glass
500 V < UN < 690 V + du/dt + N + CMF
and AM_ ** taping
N Random- UN < 420 V Standard: ÛLL = - + N or CMF + N + CMF
O wound and 1300 V
form-wound
N 420 V < UN < 500 V Standard: ÛLL = + du/dt + du/dt + N + du/dt + N + CMF
- 1300 V
or
A + du/dt + CMF
B
or
B
Reinforced: ÛLL = - + N or CMF + N + CMF
1600 V, 0.2 µs
rise time
500 V < UN < 600 V Reinforced: ÛLL = + du/dt + du/dt + N + du/dt + N + CMF
1600 V or
+ du/dt + CMF
or
Reinforced: ÛLL = - + N or CMF + N + CMF
1800 V
600 V < UN < 690 V Reinforced: ÛLL = + du/dt + du/dt + N + du/dt + N + CMF
1800 V
Reinforced: ÛLL = - N + CMF N + CMF
2000 V, 0.3 µs
rise time ***
* manufactured before 1.1.1998

** For motors manufactured before 1.1.1998, check for additional instructions with the motor manufacturer.
*** If the intermediate DC circuit voltage of the drive will be increased from the nominal level by resistor braking or
by the IGBT supply unit control program (parameter selectable function), check with the motor manufacturer if
additional output filters are needed in the applied drive operation range.
Note 1: The abbreviations used in the table are defined below.
Abbreviation Definition
UN nominal voltage of the supply network
ÛLL peak line-to-line voltage at motor terminals which the motor insulation must withstand
PN motor nominal power
du/dt du/dt filtering at the output of the drive (option +E205)
CMF common mode filtering (option +E208)
N N-end bearing: insulated motor non-driven end bearing
n.a. Motors of this power range are not available as standard units. Consult the motor manufacturer.
Note 2: Explosion-safe (EX) motors

The motor manufacturer should be consulted regarding the construction of the motor insulation and
additional requirements for explosion-safe (EX) motors.

59
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 IP23 motors, the requirements of ABB random-wound motor series M3AA, M3AP, M3BP are
given below. For other motor types, see the Requirements table above. Apply the requirements of
range “100 kW < PN < 350 kW” to motors with PN < 100 kW. Apply the requirements of range
PN > 350 kW to motors within the range “100 kW < PN < 350 kW”. In other cases, consult the motor
manufacturer.
Manufacturer

voltage (AC line
voltage)
system filter
PN < 55 kW 55 kW < PN < 200 kW PN > 200 kW
PN < 74 HP 74 HP < PN < 268 HP PN > 268 HP
A Random- UN < 500 V Standard - +N + N + CMF

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

All AMA machines (manufactured in Helsinki) for drive systems have form-wound windings. All HXR
machines manufactured in Helsinki starting 1.1.1998 have form-wound windings.
Note 5: ABB motors of types other than M2_, M3_, HX_ and AM_
Use the selection criteria given for non-ABB motors.
Note 6: Resistor braking of the drive
When the drive is in 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 21
percent. The voltage increase should be taken into consideration when determining the motor insulation
requirement.
Example: Motor insulation requirement for a 400 V application must be selected as if the drive were
supplied with 480 V.
Note 7: Drives with an IGBT supply unit
If voltage is raised by the drive (this is a parameter selectable function for special applications only),
select the motor insulation system according to the increased intermediate circuit DC voltage level,
especially in the 500 V supply voltage range.
Note 8: Calculating the rise time and the peak line-to-line voltage
The peak line-to-line voltage at the motor terminals generated by the drive as well as the voltage rise
time depend on the cable length. The requirements for the motor insulation system given in the table
are “worst case” requirements covering installations with 30-metre and longer cables. The rise time can
be calculated as follows: t = 0.8 · ÛLL/(du/dt). Read ÛLL and du/dt from the diagrams below. Multiply

60
the values of the graph by the supply voltage (UN). In case of drives with an IGBT supply unit or resistor
braking, the ÛLL and du/dt values are approximately 20% higher.
3.0
Û LL/UN
2.5
2.0
du/dt
------------- (1/μs) With du/dt Filter
UN
1.5
1.0
0.5
0.0
100 200 300
Cable length (m)
Note 9: Sine filters

Sine filters protect the motor insulation system. Therefore, a du/dt filter can be replaced with a sine
filter. The peak phase-to-phase voltage with a sine filter is approximately 1.5 × 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 a permanent magnet
synchronous motor and the motor cable. The switch is needed to isolate the motor
during any maintenance work on the drive. See also Permanent magnet motor
drives on page 10.

61
Thermal overload and short-circuit protection
Thermal overload protection of drive and cables

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

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

According to regulations, the motor must be protected against thermal overload and
the current must be switched off when overload is detected. The drive includes a
motor thermal protection function that protects the motor and switches off the current
when necessary. Depending on a drive parameter value, the function either monitors
a calculated temperature value (based on a motor thermal model) or an actual
temperature indication given by motor temperature sensors. The user can tune the
thermal model further by feeding in additional motor and load data.
The most common temperature sensors are:
• Motor sizes IEC180…225: thermal switch (e.g. Klixon)
• Motor sizes IEC200…250 and larger: PTC or Pt100.
See the firmware manual for more information on the motor thermal protection, and
the connection and use of the temperature sensors.
Protection against short-circuit in motor cable

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

The drive is equipped with input fuses that restrict drive damage and prevent
damage to adjoining equipment in case of a short-circuit inside the drive. No
additional protection devices are needed.
Protection against short-circuit in the supply (AC line) cable

Equip the input cable with fuses. Size the fuses according to local safety regulations,
appropriate input voltage and the rated current of the drive.

62
Earth fault (ground fault) protection

Both the supply unit and the inverter unit are equipped with an internal earth fault
protective function to protect the drive against earth faults in the drive, motor and
motor cable. (This is not a personal safety or a fire protection feature.) Both earth
fault protective functions can be disabled; refer to supply and inverter unit firmware
manuals. In addition to the standard earth fault monitoring, the drive can also be
equipped with an optional earth fault monitoring device (options +Q953 and +Q954).
Note: The EMC filter (if present) includes capacitors connected between the main
circuit and the frame. These capacitors and long motor cables increase the earth
leakage current and may cause fault current circuit breakers to function.
Emergency stop devices

An emergency stop function is optionally available for the cabinet-installed drives
(ACS800-07, -07LC and multidrive), (option +G331). Two modes available are:
immediate removal of power (Category 0, option +Q951) and controlled emergency
stop (Category 1, option +Q952).
For safety reasons, install the emergency stop devices at each operator control
station and at other operating stations where emergency stop may be needed.
Pressing the stop key ( ) on the control panel of the drive, or turning the operating
switch of the drive from position “1” to “0” does not generate an emergency stop of
the motor or separate the drive from dangerous potential.
Restarting after an emergency stop

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

63
Prevention of unexpected start

The cabinet-installed drive (ACS800-07, -07LC and multidrive) can be equipped with
an optional prevention of unexpected start function according to standards
IEC/EN 60204-1: 1997; ISO/DIS 14118: 1996 and EN 1037: 1996. The circuit
conforms to EN954-1, Category 3. The option code is +Q958.
The function is achieved by disconnecting the control voltage to the power
semiconductors of the inverters of the drive. Thus it is not possible for the power
semiconductors to switch and generate the AC voltage needed to rotate the motor.
In case of faulty main circuit components, the DC voltage from the busbars can be
conducted to the motor but an AC motor cannot rotate without the field generated by
an AC voltage.
The operator activates the prevention of unexpected start function using a switch
mounted on a control desk. When the function is activated, the switch is opened, and
an indicator lamp will light.
WARNING! The prevention of unexpected start function does not disconnect the
voltage of the main and auxiliary circuits from the drive. Therefore maintenance work
on electrical parts of the drive can only be carried out after isolating the drive system
from the main supply.
Note: If a running drive is stopped by using the prevention of unexpected start

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

64
Selecting the power cables
General rules
Dimension the supply (input power) and motor cables according to local
regulations:
• The cable must be able to carry the drive load current. See chapter Technical
data on page 141 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 on
page 68.
• 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. For 690 VAC rated equipment, the
rated voltage between the conductors of the cable should be minimum 1 kV.
For motors larger than 30 kW, symmetrical shielded motor cable must be used (see
figure on page 67). A four-conductor system can be used up to 30 kW motors, but
shielded symmetrical motor cable is recommended.
Note: When continuous conduit is employed, shielded cable is not required.
A four-conductor system is allowed for input cabling, but shielded symmetrical cable
is recommended. To operate as a protective conductor, the shield conductivity must
be as follows when the protective conductor is made of the same metal as the phase
conductors:
Cross-sectional area of the phase Minimum cross-sectional area of the
conductors corresponding protective conductor
S (mm2) Sp (mm 2)
S < 16 S
16 < S < 35 16
35 < S S/2
Compared to a four-conductor system, the use of symmetrical shielded cable

reduces electromagnetic emission of the whole drive system as well as motor
bearing currents and wear.
Note: The configuration of the drive may require multiple supply and/or motor
cabling (e.g. diode supply module has two parallel bridges that need to be supplied
separately). Refer to the connection diagrams in chapter Electrical installation.
The motor cable and its PE pigtail (twisted screen) should be kept as short as
possible in order to reduce electromagnetic emission as well as capacitive current.

65
Typical power cable sizes

Tables below give current carrying capacity (ILmax) for aluminium and copper
PVC/XLPE insulated cables. A correction factor K = 0.70 is used (cables laid on the
cable trays side by side, max 9 cables per tray, three ladder type trays one on top of
the other, ambient temperature 30°C, EN 60204-1 and IEC 364-5-52).
Aluminium cable PVC insulation XLPE insulation
Conductor temperature 70° Conductor temperature 90°
Size ø [mm] ILmax [A] Temp. const. [s] ILmax [A] Temp. const. [s]
3 × 35 + 10 Cu 26 69 70 86 70
3 × 50 + 15 Cu 29 83 93 104 93
3 × 70 + 21 Cu 32 107 123 134 123
3 × 95 + 29 Cu 38 130 150 163 150
3 × 120 + 41 Cu 41 151 180 189 180
3 × 150 + 41 Cu 44 174 215 218 215
3 × 185 + 57 Cu 49 199 255 249 255
3 × 240 + 72 Cu 54 235 330 294 330
2 × (3 × 70 + 21 Cu) 2 × 32 214 123 171 123
2 × (3 × 95 + 29 Cu) 2 × 38 260 150 208 150
2 × (3 × 120 + 41 Cu) 2 × 41 302 180 242 180
2 × (3 × 150 + 41 Cu) 2 × 44 348 215 278 215
2 × (3 × 185 + 57 Cu) 2 × 49 398 255 318 255
2 × (3 × 240 + 72 Cu) 2 × 54 470 330 376 330
3 × (3 × 150 + 41 Cu) 3 × 44 522 215 418 215
3 × (3 × 185 + 57 Cu) 3 × 49 597 255 478 255
3 × (3 × 240 + 72 Cu) 3 × 54 705 330 564 330
4 × (3 × 185 + 57 Cu) 4 × 49 796 255 637 255
4 × (3 × 240 + 72 Cu) 4 × 54 940 330 752 330
5 × (3 × 185 + 57 Cu) 5 × 49 995 255 796 255
5 × (3 × 240 + 72 Cu) 5 × 54 1175 330 940 330
6 × (3 × 240 + 72 Cu) 6 × 54 1410 330 1128 330
7 × (3 × 240 + 72 Cu) 7 × 54 1645 330 1316 330
8 × (3 × 240 + 72 Cu) 8 × 54 1880 330 1504 330
9 × (3 × 240 + 72 Cu) 9 × 54 2115 330 1692 330
10 × (3 × 240 + 72 Cu) 10 × 54 2350 330 1880 330

66
Copper cable PVC insulation XLPE insulation

Conductor temperature 70° Conductor temperature 90°
Size ø [mm] ILmax [A] Temp. const. [s] ILmax [A] Temp. const. [s]
3 × 1.5 + 1.5 13 13 85 16 85
3 × 2.5 + 2.5 14 18 123 23 123
(3 × 4 + 4) 16 24 177 30 177
3×6+6 18 30 255 38 255
3 × 10 + 10 21 42 354 53 354
3 × 16 + 16 23 56 505 70 505
3 × 25 + 16 24 71 773 89 773
3 × 35 + 16 26 88 970 110 970
3 × 50 + 25 29 107 1268 134 1268
3 × 70 + 35 32 137 1554 171 1554
3 × 95 + 50 38 167 1954 209 1954
3 × 120 + 70 41 193 2313 241 2313
3 × 150 + 70 44 223 2724 279 2724
3 × 185 + 95 50 255 3186 319 3186
3 × 240 + 120 55 301 3904 376 3904
2 × (3 × 70 + 35) 2 × 32 274 1554 342 1554
2 × (3 × 95 + 50) 2 × 38 334 1954 418 1954
2 × (3 × 120 + 70) 2 × 41 386 2313 482 2313
2 × (3 × 150 + 70) 2 × 44 446 2724 558 2724
2 × (3 × 185 + 95) 2 × 50 510 3186 638 3186
2 × (3 × 240 + 120) 2 × 55 602 3904 752 3904
3 × (3 × 120 + 70) 3 × 41 579 2313 723 2313
3 × (3 × 150 + 70) 3 × 44 669 2724 837 2724
3 × (3 × 185 + 95) 3 × 50 765 3186 957 3186
3 × (3 × 240 + 120) 3 × 55 903 3904 1128 3904
4 × (3 × 150 + 70) 4 × 44 892 2724 1116 2724
4 × (3 × 185 + 95) 4 × 50 1020 3186 1276 3186
4 × (3 × 240 + 120) 4 × 55 1204 3904 1504 3904
5 × (3 × 185 + 95) 5 × 50 1275 3186 1595 3186
5 × (3 × 240 + 120) 5 × 55 1505 3904 1880 3904
6 × (3 × 185 + 95) 6 × 50 1530 3186 1914 3186
6 × (3 × 240 + 120) 6 × 55 1806 3904 2256 3904
7 × (3 × 240 + 72) 7 × 55 2107 3904 2632 3904
8 × (3 × 240 + 72) 8 × 55 2408 3904 3008 3904

67
Alternative power cable types

Power cable types that can be used with the drive are represented below.
Recommended
Symmetrical shielded cable: three phase conductors A separate PE conductor is required if the conductivity
and a concentric or otherwise symmetrically of the cable shield is < 50% of the conductivity of the
constructed PE conductor, and a shield phase conductor.
PE conductor Shield
and shield Shield
PE
PE
PE Shield
A four-conductor system:
three phase conductors
and a protective
conductor.
Not allowed for motor cables Not allowed for motor cables with phase
conductor cross section larger than 10 mm 2
(motors > 30 kW).
Motor cable shield

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

Insulation jacket
Cable core

68
Additional US requirements
Type MC continuous corrugated aluminium 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 resistors, 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

6-conductor (3 phases and 3 ground) type MC continuous corrugated aluminium
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, Lapp Kabel (ÖLFLEX) and Pirelli,
among others.

69
Arranging the external power supply for the auxiliary circuit

The table below shows the four alternative means for arranging the power supply for
the auxiliary circuit of the drive.
Related drive Description Instructions

options
Case 1 +G344 Yes Drive has auxiliary voltage Transformer supplies fans. No need for external
transformer which is supplied power supply.
by drive main AC power line.
+G307 No Drive has no terminals for Transformer supplies control circuitry. No need for
external control voltage (UPS). external power supply.
Case 2 +G344 Yes Drive has auxiliary voltage Transformer supplies fans. No need for external
transformer which is supplied power supply.
by drive main AC power line.
+G307 Yes Drive has terminals for external Arrange external power supply for control circuitry:
control voltage (UPS). - See section Connection of external power supply for
the auxiliary circuits on page 94 for connection.
- Calculate load using data given in section Auxiliary
circuit current consumption on page 143. Consider
only “non-fan” load.
Case 3 +G344 No Drive has no auxiliary voltage Arrange external power supply for fans and control
transformer. circuitry:
- See section Connection of external power supply for
+G307 No Drive has no terminals for
external control voltage (UPS).
circuit current consumption on page 143.
Case 4 +G344 No Drive has no auxiliary voltage Arrange external power supply for fans:
transformer. - See section Connection of external power supply for
only fan load.
+G307 Yes Drive has terminals for external Arrange external power supply for control circuitry:
control voltage (UPS). - See section Connection of external power supply for
only “non-fan” load.

70
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 intended for use with AC
drives and can cause permanent damage to the drive or themselves.
If there are power factor compensation capacitors in parallel with the 3-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° grounding for the shields
of both the incoming and outgoing cables, or in another way connect the shields
of the cables together.
• US: Install the equipment in a metal enclosure in a way that the conduit or motor
cable shielding runs consistently without breaks from the drive to the motor.
Bypass connection
WARNING! Never connect the supply power to the drive output terminals U2, V2
and W2. If frequent bypassing is required, employ mechanically connected switches
or contactors. Mains (line) voltage applied to the output can result in permanent
damage to the unit.

71
Before opening an output contactor (in DTC motor control mode)

Stop the drive and wait for the motor to stop before opening a contactor between the
output of the drive and the motor when the DTC control mode is selected. (See the
inverter unit 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.
Relay output contacts and inductive loads

Inductive loads (such as relays, contactors, motors) cause voltage transients when
switched off.
The relay contacts of the RMIO board are protected with varistors (250 V) against
overvoltage peaks. In spite of this, it is highly recommended to equip inductive loads
with noise attenuating circuits (varistors, RC filters [AC] or diodes [DC]) 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 the protective components at the terminal block.
Relay outputs
Varistor
RO (NC)
RO (C)
230 VAC
RO (NO)
RC filter
RO (NC)
230 VAC RO (C)
RO (NO)
Diode
RO (NC)
24 VDC RO (C)
RO (NO)

72
Selecting the control cables

All control cables must be shielded.
Use a double-shielded twisted pair cable (see figure a) for analogue signals. This
type of cable is recommended for the pulse encoder signals also. Employ one
individually shielded pair for each signal. Do not use common return for different
analogue signals.
A double-shielded cable is the best alternative for low-voltage digital signals but
single-shielded twisted cable (figure b) is also usable.
a b
Double-shielded twisted Single-shielded twisted
pair cable multipair 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 from Lapp Kabel,
Germany) has been tested and approved by ABB.
Control panel cable

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

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

73
Connection of a motor temperature sensor to the drive I/O
WARNING! IEC 60664 requires double or reinforced insulation between live parts
and the surface of accessible parts of electrical equipment which are either non-
conductive or conductive but not connected to the protective earth.
To fulfil this requirement, the connection of a thermistor (and other similar

components) to the digital inputs of the drive can be implemented in three alternate
ways:
1. There is double or reinforced insulation between the thermistor and live parts of
the motor.
2. Circuits connected to all digital and analogue inputs of the drive are protected
against contact and insulated with basic insulation (the same voltage level as the
drive main circuit) from other low voltage circuits.
3. An external thermistor relay is used. The insulation of the relay must be rated for
the same voltage level as the main circuit of the drive. For connection, see the
Firmware Manual.
PELV and installation sites above 2000 metres (6562 feet)

The drive does not fulfil the Protective Extra Low Voltage (PELV) requirements
stated in EN 50178 at altitudes above 2000 m (6562 ft).
WARNING! Wear appropriate protection when installing, operating or servicing the

RMIO board wiring and optional modules attached to the board.
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° 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.

74
A diagram of the cable routing is below.
Motor cable
Drive
min. 300 mm (12 in.)
Power cable
Input power cable Motor cable
min. 200 mm (8 in.) 90°

min. 500 mm (20 in.)
Control cables
Control cable ducts

24 V 230/120 V 24 V 230/120 V
Not allowed unless the 24 V cable is insulated Lead 24 V and 230/120 V control cables
for 230 V (120 V) or insulated with an in separate ducts into the inside of the
insulation sleeving for 230 V (120 V). cabinet.

75

This chapter describes the electrical installation procedure of the drive.
WARNING! Only qualified electricians are allowed to carry out the work described in
this chapter. Follow the Safety instructions on the first pages of this manual. Ignoring
the safety instructions can cause injury or death.
Before installation
Checking the insulation of the assembly
WARNING! Before start, read and follow the instructions given in chapter Safety
instructions. Ignoring the instructions can cause physical injury or death, or damage
to the equipment.
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:
• Check that all motor cables are disconnected from the drive output terminals U2,
V2 and W2.
M • Measure the insulation resistance 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.
Checking the compatibility with IT (ungrounded) systems

EMC filter +E202 is not suitable for use in an IT (ungrounded) system. If the drive is
equipped with EMC filter +E202, disconnect the filter before connecting the drive to
an ungrounded power line. For detailed instructions on how to do this, please
contact your local ABB representative.
76
WARNING! If a drive with EMC filter +E202 is installed on an IT system [an

ungrounded power system or a high resistance-grounded (over 30 ohms) power
system], the system will be connected to earth potential through the EMC filter
capacitors of the drive. This may cause danger, or damage the unit.
Input power and charging circuit connection – drives without a built-

in main breaker (no option +F255) or contactor (+F250)
Connection diagram – 6-pulse units

U<
Bridging is installed
at the factory for a
6-pulse unit. Do not
remove!
max. 50 A
1)
1L1.1
1L2.1
1L3.1
1L1.2
1L2.2
1L3.2
10 mm2
PE
Q2.1
3
Q2.2
Charging circuit 1)
Supply module cubicle DC bus
Notes:
1) With a half-controlled input bridge (option +A018), no charging circuit and no external wiring for it are needed.
The figure shows the connection of a supply unit with one D4 module. The connection principle is the same with D3 (then
the module contains only one bridge) and multiple modules.
The main breaker is to be acquired and installed by the customer.
For selection of the input power cables, see chapter Selecting the power cables on page 72
For the power cable terminal sizes and cabinet lead-through sizes, see section Units without built-in main breaker or
contactor (no option +F250 or +F255) on page 150.
For the power cable terminal tightening torques, see section Connection procedure – 6-pulse to 24-pulse units on
page 80.
77
Connection diagram – 12-pulse units (option +A004)

U<
U<
max. 50 A
10 mm2
1)
1L1.1
1L2.1
1L3.1
1L1.2
1L2.2
1L3.2
PE
Q2.1
3
Q2.2
Charging circuit 1)
Supply module cubicle DC bus
Notes:
1)
With a half-controlled input bridge (option +A018), no charging circuit and no external wiring for it are needed.
The figure shows the connection of a supply unit with one D4 module. The connection principle is the same with multiple
modules.
Pay special attention to the connection of the two bridges inside each module. For a 12-pulse connection, bridge 1 and
bridge 2 must be supplied either from separate transformers or separate transformer secondary windings. For the supply
transformer specification, see section Transformer for a 12-, 18- and 24 -pulse supply on page 154.
The main breakers are to be acquired and installed by the customer.
For selection of the input power cables, see section Selecting the power cables on page 72.
For the power cable terminal sizes and cabinet lead-through sizes, see section Input busbar and lead-through data on
page 150.
For the power cable terminal tightening torques, see section Connection procedure – 6-pulse to 24-pulse units on page 80.
78
U<
U<
U<
max. 50 A
1)
1L3.3
1L2.3
10 mm2
1L1.3
1L1.1
1L2.1
1L3.1
1L1.2
1L2.2
1L3.2
PE
Q2.1
3
Q2.2
Charging circuit 1)
Supply
module
Supply module cubicle 1 DC bus cubicle 2
Notes:
1)
With a half-controlled input bridge (option +A018), no charging circuit and no external wiring for it are needed.
For the other notes, see section Connection diagram – 12-pulse units (option +A004) on page 77.
79

U<
U<
U<
U<
max. 50 A
10 mm2 1)
1L1.3
1L2.3
1L3.3
1L1.4
1L2.4
1L3.4
1L1.1
1L2.1
1L3.1
1L1.2
1L2.2
PE 1L3.2
Q2.1
3
Q2.2
Charging circuit 1)
Supply module
Supply module cubicle 1 DC bus cubicle 2
Notes:
1) With a half-controlled input bridge (option +A018), no charging circuit and no external wiring for it are needed.
For the other notes, see section Connection diagram – 12-pulse units (option +A004) on page 77.
80
Connection procedure – 6-pulse to 24-pulse units
WARNING! Read and follow the instructions given in chapter Safety instructions.
Ignoring the instructions can cause physical injury or death, or damage to the
equipment.
1. Open the door of the supply module cubicle: Unlock the handle, release it from
the holder and turn upwards to release the door locking mechanism.
2. Remove the shroud that protect the input busbars and cable entries (four screws).
3. Unplug the socket of the cooling fan and remove the cooling fan. See section
Replacing the fan of the diode supply module cubicle on page 110 for instructions.
4. Units with charging resistors (no option +A018): Lead the charging circuit
cable into the inside of the cubicle to the appropriate terminal block, and connect.
5. Lead the input power cables into the inside of the cubicle. It is recommended to
apply 360° grounding of the cable shields at the entry.
6. Connect the input power cables:
- Cut the cables to suitable length. Strip the cables and conductors. Fasten
cable lugs to the conductor ends.
- Twist the cable shields into bundles and connect to cabinet PE (ground)
busbar. Connect also any separate ground conductors or cables to cabinet PE
busbar.
- Connect the phase conductors to the input power terminals. Depending on the
supply connection principle, see the appropriate connection diagram above.
- Tighten the phase conductors and PE to 70 Nm (50 lbf.ft) torque.
7. Refit the fan and plug in the fan socket.
8. Refit the shroud removed earlier and close the door.
81
Supply module cubicle Supply module cubicle

from front, door closed from front, door open
Lower half of the supply module cubicle from front, Supply module from below,
shroud removed, cooling fan in place shroud and cooling fan removed
3
6
Grommet (in IP54 units

only)
6
82
Input power connection – drives with built-in main breaker (option +F255)
or contactor (option +F250)
Connection diagram – 6-pulse units (option +F255 or +F250)

Bridging is installed at
U< 2) the factory for a 6-pulse
unit (also between the
L1
parallel modules). Do
not remove!
L2
L3
PE
Charging circuit 1)
Incoming cubicle Supply module

cubicle
DC bus
Notes:
1)
There is no charging circuit with a half-controlled input bridge (option +A018).
modules.
2) Units
with option +F250 have a contactor and a switch fuse (OESA) instead of a breaker.
For selection of the input power cables, see section Selecting the power cables on page 64.
For the power cable terminal sizes and cabinet lead-through sizes, see section Units with built-in main breaker (option
+F255) on page 151.
For the power cable terminal tightening torques, see section Connection procedure – 6- to 24-pulse units on page 86.
83
Connection diagram – 12-pulse units (options +A004 and +F255 or +F250)
U< 2)
1L1.2
1L2.2
1L3.2
PE U<
1L1.1
1L2.1
1L3.1
1)
Charging circuit 1)
Incoming cubicle Supply module

cubicle
DC bus
Notes:
1)
2) Units with option +F250 have a contactor and a switch fuse (OESA) instead of a breaker.
modules.
Pay special attention to the connection of the two bridges inside each module. For a 12-pulse connection, bridge 1 and
bridge 2 must be supplied either from separate transformers or separate transformer secondary windings. For the supply
transformer specification, see section Transformer for a 12-, 18- and 24 -pulse supply on page 154
For selection of the input power cables, see chapter see section Selecting the power cables on page 64.
For the power cable terminal sizes and cabinet lead-through sizes, see section Input busbar and lead-through data on
page 150.
For the power cable terminal tightening torques, see section Connection procedure – 6- to 24-pulse units on page 86.
84
2)
U<
1L1.3
1L2.3
1L3.3
PE
U<
1L1.2
1L2.2
1L3.2
PE
U<
1L1.1
1L2.1
1L3.1
1)
Charging circuit 1)
Incoming cubicles Supply module Supply

cubicle 1 module
DC bus cubicle 2
Notes:
1) There is no charging circuit with a half-controlled input bridge (option +A018).
2)
Units with option +F250 have a contactor and a switch fuse (OESA) instead of a breaker.
For the other notes, see section Connection diagram – 12-pulse units (options +A004 and +F255 or +F250) on page 83
85

U<
2)
1L1.4
1L2.4
1L3.4
PE
U<
1L1.3
1L2.3
1L3.3
PE
U<
1L1.2
1L2.2
1L3.2
PE
U<
1L1.1
1L2.1
1L3.1
1)
Charging circuit 1)
Incoming cubicles Supply module Supply module

cubicle 1 DC bus cubicle 2
Notes:
1)
2) Units
with option +F250 have a contactor and a switch fuse (OESA) instead of a breaker.
For the other notes, see section Connection diagram – 12-pulse units (options +A004 and +F255 or +F250) on page 83
86
Connection procedure – 6- to 24-pulse units
equipment.
1. Open the door of the incoming cubicle. Unlock the handle, release it from the
holder and turn upwards to release the door locking mechanism.
2. Remove the shroud that protect the input busbars and cable entries.
3. Lead the input cables into the inside of the cubicle. It is recommended to apply
360° grounding of the cable shields at the entry.
4. Connect the cables:
- Cut the cables to suitable length. Strip the cables and conductors. Fasten
busbar. Connect also any separate ground conductors or cables to cabinet PE
busbar.
- Connect the phase conductors to the input power terminals. Depending on the
connection principle see the appropriate connection diagram above.
Incoming cubicle from front, Incoming cubicle from Lower part of the incoming cubicle from front,
door closed front, door open shroud removed
Grommet (in IP54

units only)
2
4
87
Motor connection – Frame R8i without the Common Motor Terminal

cubicle (no option +H359) or Common Motor Terminal connection (no
option +H366)
Connection diagram – single inverter module feeds one motor
PE
W2
V2
W1
V1
M
U2
U1 3~
PE
Inverter unit cubicle

Note:
For selection of the motor cables, see section Selecting the power cables on page 64.
Pay special attention to the grounding of the cable. 360° earthing is to be used at cable entries both
at the inverter end and at the motor end.
For the power cable terminal sizes and cabinet lead-through sizes, see section Input busbar and
lead-through data on page 150.
For the power cable terminal tightening torques, see section Connection procedure on page 93.
Connection diagram – parallel inverter modules feed one motor
PE
W2
V2
U2
W1
V1
M
U1 3~
W2 PE
V2
U2

Notes:
For selection of the motor cables, see chapter Planning the electrical installation.
For the power cable terminal sizes and cabinet lead-through sizes, see chapter Technical data.
88
WARNING! The cabling from all inverter modules to the motor must be physically
identical considering cable type, cross-sectional area, and length.
PE
W2
V2
U2
W1
V1
M
U1 3~
W2 PE
V2
U2
89
Connection procedure
equipment.
1. Open the door of the inverter module cubicle: Unlock the handle, release it from
the holder and turn upwards to release the door locking mechanism.
2. Remove the shroud that protect the output busbars and cable entries.
3. Unplug the socket of the cooling fan and remove the cooling fan. See Replacing
the fan in the inverter module cubicle (frame size R8i) on page 113.
4. Lead the cables into the inside of the cubicle. For minimum radio frequency
interference and motor bearing current, ground the cable shield 360° at the lead-
through.
5. Connect the cables as follows:
- Cut the cables to suitable length. Strip the cables and conductors. Fasten the
- Twist the cable shields into bundles and connect to cabinet ground busbar.
- Connect the phase conductors to the output terminals. See the appropriate
connection diagram above.
6. Plug in the fan power supply and refit the fan.
8. Connect the motor end of the cable. See the diagrams above. For minimum radio
frequency interference and motor bearing current ground the cable shield 360° at
the lead-through of the motor terminal box, or ground the cable by twisting the
shield as follows: flattened width > 1/5 × length. For the motor specific
instructions, see the manufacturer’s user manual.
90
Inverter module cubicle from Inverter module cubicle from Lower part of the inverter module cubicle from front,
front, door closed front, door open shroud removed
Terminals are
5
behind the fan.
1
3 3
360° grounding of the cable shield Alternative cable shield grounding means at the
at the inverter end motor end
8
4
Alternative 1:
360° grounding of the shield
Conductive gasket
Grommet (in Alternative 2:

IP54 units only) grounding the twisted b > 1/5 × a
shield
b
a
91
Motor connection – Units with the Common Motor Terminal connection

(option +H366)
Connection diagram
Connect the motor cables directly to the output busbars of the inverter modules.
However, as there are bridging busbars between the inverter module outputs, it is
possible to arrange the cables asymmetrically between the modules. E.g. In case of
two parallel inverter modules it is possible to use three parallel cables to supply the
motor. See the diagram below. The bridging balances the motor current between the
modules.
PE
W2
V2
U2
Bridging is installed at the

W1
V1
M
factory. Do not remove!
U1 3~
W2 PE
V2
U2
WARNING! The bridging can carry the nominal output current of one inverter module. In case of three
parallel modules, ensure that the load capacity of the bridging is not exceeded. I.e. if the cabling
connects to the output busbars of one module only, use the module in the middle.
Notes:
Always use identical symmetric three phase cables. For selection of the motor cables, see chapter
Selecting the power cables on page 64.
Pay special attention to the grounding of the cable. 360° earthing is to be used at cable entries both at
the inverter end and at the motor end.
For the power cable terminal sizes and cabinet lead-through sizes, see section Units without the
Common Motor Terminal cubicle (no option +H359) on page 152.
See Connection procedure on page 89.
92
Motor connection – Units with the Common Motor Terminal cubicle

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

Terminal cubicle
Notes:
For selection of the motor cables, see section Selecting the power cables on page 64.
For the power cable terminal sizes and cabinet lead-through sizes, see section Input busbar and
lead-through data on page 150.
93
WARNING! Before start, read and follow the instructions given in chapter Safety
instructions. Ignoring the instructions can cause physical injury or death, or damage
to the equipment.
The numbers in brackets refer to the photos below.

1. Open the door of the Common Motor Terminal cubicle: Unlock the handle, release
it from the holder and turn upwards.
2. Remove the shrouds that protect the output busbars and cable entries.
3. Lead the cables into the cubicle. For minimum radio frequency interference and
motor bearing current, ground the cable shield 360° at the lead-through.
4. Connect the cables as follows:
- Cut the cables to suitable length. Strip the cables and conductors. Fasten the
busbar.
- Connect the phase conductors to the output terminals. See the Connection
diagram above.
5. Refit the shrouds and close the door.
6. At the motor, connect the cables according to the Connection diagram above. For
minimum radio frequency interference and motor bearing current ground the
cable shield 360° at the lead-through of the motor terminal box, or ground the
cable by twisting the shield as follows: flattened width > 1/5 × length. For the
motor specific instructions, see the manufacturer’s user manual.
3 6 360° grounding
Conductive gasket
Grommet (in IP54 b > 1/5 × a

units only)
b
a
94
Connection of external power supply for the auxiliary circuits

There are four alternative means to arrange the power supply for the auxiliary circuit
(= fans and control circuitry). See section Arranging the external power supply for
the auxiliary circuit on page 69 for details. This section illustrates the user
connections for those three cases (case 2, 3 and 4) in which the drive fan and/or
control circuitry must have an external supply. Note that case 1 – drive with an
auxiliary voltage transformer and with no terminals for external control voltage (UPS)
– does not require any external wiring and therefore it is not shown here.
Connection diagram, case 2
L1
L2
L3
Option selections
+G344 Auxiliary transformers = Yes
+G307 Terminals for external = Yes
control voltage (UPS)
PE
L
1
2
Q12
1
2
Q11
>
>
L N
L N
Power supply for control circuitry Power supply for fans
Note:
Connect the external auxiliary power supply for control circuitry to Q11. Breakers Q11 and Q12 are
located in the diode supply cubicle.
95
Power supply for control

circuitry and fans
L N PE
1
2
1
2
3
Q11 Q12
Option selections
+G344 Auxiliary transformers = No
> > +G307 Terminals for external = No
control voltage (UPS)
Note:
Connect the external auxiliary power supply (control circuitry and fans) to Q11. Breakers Q11 and
Q12 are located in the diode supply cubicle.
Power supply for control circuitry Power supply for fans
L N PE L N PE
1
2
1
2
Q11 Q12
Option selections
+G344 Auxiliary transformers = No
+G307 Terminals for external = Yes
> > control voltage (UPS)
Note:
Connect the external auxiliary power supply to Q11 (control circuitry) and Q12 (fans). Breakers Q11
and Q12 are located in the diode supply cubicle.
96
External control connections to the inverter unit

The user controls the operation of the motor (start, stop, direction, speed, etc.) with
the inverter unit control panel, or through the inverter control connections, see
Inverter unit control interfaces on page 36. The connections to standard IO terminals
are either made directly to the control unit (RDCU) or to terminal block X2 (option
+L504). X2 is wired to the RDCU at the factory. The RDCU and X2 are located in the
swing-out frame of the inverter cubicle. Additional information of the control
connections is available as follows:
• Connections to standard IO terminals: See the appropriate I/O connection
diagram below and the circuit diagrams delivered with the drive.
• Control cable routing and grounding instructions: See Control cable connection
procedure on page 100.
• Connections to fieldbus adapter modules (options +K451, +K452, etc.), IO
extension modules (options +L500 or +L501), pulse encoder module (+L503) or
PC: See Installation of optional modules and PC on page 101 and the option
module specific manual delivered with the drive.
• Connections of hardware options such as motor temperature protections (options
+L505 or +L506), power supply for motor cooling fan (e.g. +M604), etc.: See the
circuit diagrams delivered with the drive.
97
IO connection diagram (non-US version of the Standard Application Program)

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 Standard Application
Program Firmware Manual (code: 3AFE64527592 [English]).
X2* RMIO
X20 X20
RMIO 1 1 VREF- Reference voltage -10 VDC, 1 kohm < RL <
Terminal block size: 2 2 AGND 10 kohm
cables 0.3 to 3.3 mm2 (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, Rin >
4 4 AI1- 200 kohm
5 5 AI2+ By default, not in use. 0(4)... 20 mA, Rin =
6 6 AI2- 100 ohm
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, RL < 700 ohm
* optional terminal block (not in all units) X22 X22
1) Only effective if par. 10.03 is set to 1 1 DI1 Stop/Start
REQUEST by the user. 2 2 DI2 Forward/Reverse 1)
3 3 DI3 Not in use
2) 0 = open, 1 = closed 4 4 DI4 Acceleration & deceleration select 2)
DI4 Ramp times according to 5 5 DI5 Constant speed select 3)
0 parameters 22.02 and 22.03 6 6 DI6 Constant speed select 3)
1 parameters 22.04 and 22.05 7 7 +24VD +24 VDC max. 100 mA
8 8 +24VD
3)
See par. group 12 CONSTANT
9 9 DGND1 Digital ground
SPEEDS.
DI5 DI6 Operation
11 11 DIIL Start interlock (0 = stop) 4)
0 0 Set speed through AI1
1 0 Constant speed 1 X23 X23
0 1 Constant speed 2 1 1 +24V Auxiliary voltage output and input, non-
1 1 Constant speed 3 2 2 GND isolated, 24 VDC 250 mA 5)
X25 X25
4) See parameter 21.09 START INTRL 1 1 RO1 Relay output 1: ready
FUNC. 2 2 RO1
5) Total maximum current shared
3 3 RO1
between this output and optional
modules installed on the board. X26 X26
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
98
IO connection diagram (US version of the Standard Application Program)

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 Standard
Application Program Firmware Manual (code: 3AFE64527592 [English]).
X2* RMIO
RMIO X20 X20
Terminal block size: 1 1 VREF- Reference voltage -10 VDC, 1 kohm < RL <
2 2 2 AGND 10 kohm
cables 0.3 to 3.3 mm (22 to 12 AWG)
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, Rin >
4 4 AI1- 200 kohm
6 6 AI2- 100 ohm
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, RL < 700 ohm
X22 X22
1 1 DI1 Start ( )
2 2 DI2 Stop ( )
* optional terminal block (not in all units)
3 3 DI3 Forward/Reverse 1)
1)
Only effective if par. 10.03 is set to 4 4 DI4 Acceleration & deceleration select 2)
REQUEST by the user. 5 5 DI5 Constant speed select 3)
6 6 DI6 Constant speed select 3)
2)
0 = open, 1 = closed 7 7 +24VD +24 VDC max. 100 mA
DI4 Ramp times according to 8 8 +24VD
0 parameters 22.02 and 22.03 9 9 DGND1 Digital ground
1 parameters 22.04 and 22.05
3)
11 11 DIIL Start interlock (0 = stop) 4)
See par. group 12 CONSTANT
SPEEDS.
X23 X23
DI5 DI6 Operation
1 1 +24V Auxiliary voltage output and input, non-
2 2 GND isolated, 24 VDC 250 mA 5)
0 0 Set speed through AI1
1 0 Constant speed 1 X25 X25
0 1 Constant speed 2 1 1 RO1 Relay output 1: ready
1 1 Constant speed 3 2 2 RO1
3 3 RO1
4) See parameter 21.09 START INTRL
X26 X26
FUNC. 1 1 RO2 Relay output 2: running
5) Total maximum current shared
2 2 RO2
between this output and optional
modules installed on the board. 3 3 RO2
X27 X27
1 1 RO3 Relay output 3: fault (-1)
Fault 2 2 RO3
3 3 RO3
99
External control connections to the supply unit

The supply unit is typically controlled using the local control devices mounted on the
cabinet door, i.e. the start switch, reset button and emergency stop button. No other
control devices are used or needed typically. However, if the drive is not equipped
with the built-in main breaker or contactor (option +F255 or +F250), the external
control and supervision circuits of the external breaker must be connected to the
supply unit. Also, it is possible that the supply unit is equipped with options that
require some external connections. The table below lists the possible connections to
consider.
Control connection Information/instructions
Connections of main breaker/ See the circuit diagrams delivered with the unit for the terminal designations.
contactor control and supervision See Control cable connection procedure on page 100 for the cabling
circuits (no option +F255 or +F250) instructions.
Note: The terminal blocks for the user connections are located near the cable
entry of the supply unit cubicle.
Connection of external emergency Wire the external buttons in series with the cabinet-installed emergency stop
stop buttons button. See the circuit diagrams delivered with the drive.
See Control cable connection procedure below for the cabling instructions.
Note: The terminal blocks for the user connections are located near the cable
entry of the supply unit cubicle.
Connection to fieldbus adapter See the option module specific manual delivered with the drive for the
module connection terminals.
See Control cable connection procedure below and Installation of optional
modules and PC on page 101 for the cabling details.
Note: The option modules are attached to the RDCU unit which is located in
the swing out frame.
Connection of PC Connect the PC via a fibre optic link to RDCO board CH3.
See Control cable connection procedure below for the cabling details.
Note: RDCO is attached to the RDCU unit which is located in the swing-out
frame.
Connection of hardware option See the circuit diagrams delivered with the unit.
100
Control cable connection procedure

WARNING! Before start, read and follow the instructions given in chapter Safety instructions.
Ignoring the instructions can cause physical injury or death, or damage to the equipment.
Open the cabinet door(s).

Remove any shrouds that limit access to the cable lead-throughs and cable trunking.
Run the cables into the inside of the cabinet through the grommets provided.
Top entry units only: If several cables need to be run through one grommet, use Loctite 5221 (cat. no.
25551) under the grommet to seal the cable entry.
Units with EMI conductive cushions only:
Run the cables between the cushions as shown below. Strip the cable at this location to enable proper
connection of the bare shield and the cushions. Tighten the cushions firmly onto the cable shields.
Side view
Strain relief EMI conductive
cushions
Grommet Lead-through plate
If the outer surface of a cable shield is non-conductive, turn the shield inside out as shown below and
apply copper foil to keep the shielding continuous. Do not cut the grounding wire (if present).
Stripped cable Conductive surface of Stripped part covered

the shield exposed with copper foil
Copper foil
Cable shield Shielded twisted pair
Grounding wire
On top entry units, sort the cables so that the thinnest and thickest cables are at opposite ends of the
opening.
Top view
Thickest cable Thinnest cable
101
Run the cables to the appropriate terminals. Wherever possible, use the existing cable trunking in the
cabinet. Use sleeving wherever the cables are laid against sharp edges.
Note: When running cables to the swing-out frame, leave some slack in the cable at the hinge to allow the
frame to open fully. Tie the cables to the cable supports wherever necessary.
Cut the cables to suitable length. Strip the cables and conductors.
Twist the cable shields into bundles and connect them to the ground terminal nearest to the terminal block.
Keep the unshielded portion of the cables as short as possible.
Connect the conductors to appropriate terminals (see External control connections to the inverter unit on
page 96 and the circuit diagrams delivered with the unit).
Refit any shrouds removed earlier. Close the cabinet door(s).
Installation of optional modules and PC
PC connection
equipment.
Connect PC to CH3 of RDCO board via a fibre optic link. RDCO is attached to an
option slot of the RDCU unit. See also Fibre optic links below.
Installation of option modules
equipment.
Insert optional modules (such as fieldbus adapters, I/O extension modules and pulse
encoder interfaces) into the optional module slots of the RDCU unit and secure with
two screws. The slots on the RDCU unit are described in Inverter unit control
interfaces on page 36. See also the appropriate optional module manual for
information on the cable connections.
102
Cabling of I/O and fieldbus modules
Module
Keep unshielded portion as
short as possible
Shield
1
2
3
4
To nearest PE terminal
Cabling of pulse encoder interface module
CHASSIS
RTAC-01
PULSE ENCODER INTERFACE
GND
Note 1: If the encoder is of unisolated
12345678 123456
SHLD
F01
type, ground the encoder cable at the
CDE
23 6
SHLD
45
AB
789
CHA
drive end only. If the encoder is

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

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

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

DDCS fibre optic links are provided by RDCO module for PC tools, master/follower
link, NDIO, NTAC, NAIO, AIMA I/O module adapter and fieldbus adapter modules of
type Nxxx. See the RDCO User’s Manual [3AFE64492209 (English)] for the details.
Observe colour coding when installing fibre optic cables. Blue connectors go to blue
terminals, and grey connectors to grey terminals.
When installing multiple devices on the same channel, connect them in a ring.
103
Check the mechanical and electrical installation of the drive before start-up. Go
through the checklist below together with another person.
WARNING! Read and follow the instructions given in Safety instructions. Ignoring
Check…
MECHANICAL INSTALLATION
The ambient operating conditions are within the allowed limits. See chapter Technical data.
The unit has been fixed properly to floor, and if necessary (e.g. marine application) also to the wall.
ELECTRICAL INSTALLATION See chapters Planning the electrical installation, Electrical installation.
The motor and the driven equipment are ready for start.
The drive is grounded properly.
The supply (input power) voltage matches the nominal input voltage of the drive.
The supply (input power) connection to the input terminals is OK.
Appropriate supply (input power) disconnector is installed.
The motor connections at the output terminals are OK.
The motor cable is routed away from other cables.
No power factor compensation capacitors are connected to the motor cable.
The external control connections to the drive are OK.
There are no tools, foreign objects or dust from drilling inside the drive.
Supply (input power) voltage cannot be connected to the output of the drive (with a bypass connection).
For drives with Category 1 Emergency stop function (option +Q952): The time relay has been set to a suitable
value (e.g. somewhat longer than the stop ramp of the inverter units).
COOLING CIRCUIT See chapter The internal cooling circuit.
The cooling circuit joints at the shipping split joining cubicles are tight.
Bleed and drain valves in all cubicles are closed.
104
105
Start-up
Action Additional information

WARNING! Ensure that the disconnector of the supply transformer is
locked to open position, i.e. no voltage is, or cannot be connected to
drive inadvertently. Check also by measuring that there is no voltage
connected.
Basic checks with no voltage connected
If the unit is equipped with an air circuit breaker, check the current trip Optional device. See the delivery
limits of the breaker (preset at the factory). specific circuit diagrams.
General rule
Ensure that the selectivity condition is fulfilled i.e. the breaker trips at a
lower current than the protection device of the supplying network, and
that the limit is high enough not to cause unnecessary trips during the
intermediate DC circuit load peak at start.
Long-term current limit
As a rule of thumb, this should be set to the rated AC current of the
module.
Peak current limit
As a rule of thumb, this should be set to a value 3-4 times the rated AC
current of the module.
Check the settings of the relays and breakers/switches of the auxiliary Optional devices. See delivery
circuits. specific circuit diagrams.
Disconnect any unfinished or unchecked 230/115 VAC cables that lead
from the terminal blocks to the outside of the equipment.
Locate the PPCS branching unit (APBU-xx) at the inverter cubicle swing By default, memory backup is
out frame. Enable memory backup battery by setting actuator 6 of switch switched off to save the battery.
S3 to ON.
Fill up and bleed the internal cooling circuit. Ensure that the coolant can See chapter The internal cooling
flow freely in all cubicles. Start the cooling unit up. circuit. For drives with the optional
cooling unit (option codes +C140 or
+C141), see ACS800-1007LC User’s
Manual (3AFE68621101 [English])
Install all shrouds and close the doors.

Connecting voltage to input terminals and auxiliary circuit
WARNING! When voltage is connected to the input terminals, voltage
may also be connected to the auxiliary circuits of the drive.
Make sure that it is safe to connect voltage. Ensure that:
• nobody is working on the unit or circuits that are wired from outside into
the cabinets
• cabinet doors are closed
• covers of motor terminal boxes are in place.
Start-up
106
Action Additional information

Units that have earthing/grounding switch (option +F259): The earthing/grounding switch and
Open the grounding switch. the main disconnecting device are
either mechanically or electrically
interlocked so that the earthing/
grounding switch can only be closed
when the main disconnecting switch
is open, and vice versa.
Close the main breaker of the supply transformer.
Close the supply unit disconnector. Units that have a withdrawable
circuit breaker (option +F255):
Unlock the withdrawn breaker and
push it to closed position.
Starting the supply unit
WARNING! If the drive is equipped with a brake unit, make sure there If there is not enough capacitive load
are inverters connected to the intermediate circuit before start. As a rule at start, the DC voltage will overshoot
of thumb, the sum capacitance of the inverters connected must be at the controller voltage limit, causing
least 30% of the sum capacitance of all inverters. immediate start of braking. An
unloaded supply unit keeps the DC
voltage high and the chopper
remains conductive.
Close the breaker and start the supply unit by turning the start switch on
the cabinet door from 0 into START position for 2 seconds, leave to ON
(I) position.
Checks with the supply unit running
Units with earth (ground) fault monitoring device (options +Q953 or Optional device. See delivery
+Q954): specific circuit diagrams and the
Check the settings of the earth fault (ground fault) monitoring device. manual delivered with the monitoring
device.
Manuals by Bender (manufacturer): IRDH265 manual (code: TGH1249
en), IRDH275/IRDH275B manual (code: THG1361en.)
Inverter unit application program set-up
Follow the instructions in the Firmware Manual to start up the drive and
to set the drive parameters.
On-load checks
Units with the Prevention of Unexpected Start function included Optional function. See delivery
(option code +Q950): specific circuit diagrams.
Check that the circuit is connected and works:
• Start and stop the drive and wait until the motor has stopped.
• Open the Prevention of Unexpected Start switch (mounted on a control
desk).
• Give a start command. The drive must not start.
• Reset the drive.
Check the direction of rotation of the motor.
Check the correct operation of the emergency-stop circuits from each Optional function. See delivery
operating location. specific circuit diagrams.
Make the on-load checks and adjustments of the cooling unit For drives with the optional cooling
unit (option code +C140 or +C141),
see ACS800-1007LC User’s Manual
(3AFE68621101 [English])
Start-up
107
Fault tracing

This chapter instructs in interpreting the LED indications of the drive. Information on
the warning and fault messages of the drive is given in the Firmware Manuals
delivered with the drive.
LEDs of the drive
Location LED Indication
RMIO board (RDCU drive control Red Drive in fault state.

unit)
Green The power supply on the board is OK.
Control panel mounting platform Red Drive in fault state.
(with the control panel removed)
Green The main + 24 V power supply for the control panel and the
RMIO board is OK.
AINT board (visible through the V204 (green) +5 V voltage of the board is OK.
transparent cover on the front of the
V309 (red) Prevention of unexpected start is ON.
inverter modules)
V310 (green) IGBT control signal transmission to the gate driver control
boards is enabled.
DSCB board V23 (green) Power +15 V is OK.
V24 (green) Reserved for future use.
V25 (green)
V26 (green)
V32 (green)
APBU board “RXD” led Data is being received from RDCU drive control unit.
“TXD” led Data is being sent to RDCU drive control unit.
“BAT” led Memory backup battery voltage is OK.
“PWR” led 5 V power to on-board logic is OK.
Fault tracing
108
Fault tracing
109
Maintenance

This chapter contains a table of preventing maintenance intervals, detailed
preventive maintenance instructions, and instructions on how to replace the supply
and inverter modules.
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 action Instructions
See document ACS800 Capacitor Reforming

Every year of
Capacitor reforming Guide (Code: 3BFE 64059629 [English]) and
storage
section Capacitors on page 127.
Adding corrosion inhibitor

Add inhibitor. Amount and type: see chapter The
Every 2 years to the internal cooling
internal cooling circuit, page 129.
circuit
Every 6 years Change of fans See section Cooling fans on page 110.
PPCS branching unit Locate the APBU unit. Switch off the power to
Every 6 years (APBU-xx) – Memory the unit. Remove cover. Replace battery with a
backup battery renewal new CR 2032 battery.
Every 12 years Capacitor change Contact an ABB service representative.
Note: If the drive is equipped with the cooling unit (option +C140 or +C141), see
also the maintenance intervals given in ACS800-1007LC User’s Manual
(3AFE68621101 [English]).
Maintenance
110
Cooling fans
Replacing the fan of the diode supply module cubicle
WARNING! Read and follow the instructions in chapter Safety instructions. Ignoring
1. Ensure that the drive is disconnected from the power line and all other
precautions described in section Installation and maintenance work on page 6 of
chapter Safety instructions have been taken into consideration.
2. Open the door and remove the lower shroud of the cubicle.
3. Units with charging resistors (without option +A018): Remove the four
mounting screws of the charging unit and pull the unit slightly outwards.
4. Units with charging resistors (without option +A018): Unplug the two wire
sets connecting the charging unit to the converter module.
5. Units with charging resistors (without option +A018): Unplug the wire set
connecting the charging unit to terminal block at the lower part of the cubicle.
6. Units with charging resistors (without option +A018): Remove the charging
unit.
7. Unplug the fan power supply.
8. Remove the six screws that connect the fan frame to the cubicle and pull the
frame out of the cubicle.
9. Remove the four screws that fasten the fan to the fan frame.
10. Install a new fan in reverse order.
3
4
5
8
9
7
Maintenance
111
Replacing the fan in 400 mm wide incoming cubicle

There is 400 mm wide incoming cubicle in units with option +F250 (line contactor).
precautions described in Installation and maintenance work on page 6 of
2. Open the door and remove the shroud to gain access to the fan.
3. Remove the four mounting screws of the fan.
4. Unfasten the power supply cable of the fan and pull the fan out of the cubicle.
5. Remove the four screws that fasten the fan and the fan grille.
Maintenance
112
Replacing the fan in 600 mm or 1000 mm wide incoming cubicle

There is either a 600 mm or a 1000 mm wide incoming cubicle in units with option
+F255 (main breaker contactor).
3. Remove the four mounting screws of the fan.
4. Unfasten the power supply cable of the fan and pull the fan out of the cubicle.
5. Remove the four screws that fasten the fan and the fan grille.
600 mm wide cubicle 1000 mm wide cubicle
5
5 3
Maintenance
113
Replacing the fan in the inverter module cubicle (frame size R8i)
3. Remove the two screws that fasten the fan collar to the cabinet frame.
4. Unplug the power supply cable of the fan and slide the fan and the collar out of
the cubicle.
5. Remove the two screws that fasten the fan to the support plate at front.
6. Remove the four screws that fasten the fan output flange to the fan collar.
Maintenance
114
Supply module D3 and D4 replacement
1. Ensure that the drive is disconnected from the power line and that all other
2. Remove the shrouds: metal grating at the lower part of the cubicle (four screws),
and two plastic shrouds, one at the upper part of the cubicle and one at the
middle (four screws each). Remove also the supports of the upper shroud. Mark
down the position and facing of the supports!
3. Close the inlet (a) and outlet (b) valves of the cubicle, and drain the cooling
circuit (see Draining the internal cooling circuit on page 132. Note: Drain (d) and
bleed (c) valves have locking handles. Release the mechanism before turning.
4. Remove the fan. See Replacing the fan of the diode supply module cubicle on
page 110.
5. Unplug the connector that connects to the bottom of the module. First loosen the
two screws that fasten the connector to its counterpart (3 mm slotted head).
6. Remove the AC fuses: Loosen the screws on both sides and pull the fuses off.
7. Remove the four bolts that fasten the bottom of the module to the cabinet
support frame: two to back and two to sides of the cubicle.
8. Fasten the right-hand side support of the winch to the support frame of the
cubicle (four screws). Fasten the left-hand side support of the winch to the
support frame of the cubicle (four screws). Note: Position the guide pins of the
supports in the holes of the cabinet frame before tightening the screws. For
detailed instructions, see Installing the winch on page 124.
Maintenance
115
2 Removing the shrouds 3 Draining the cooling circuit 4 Removing the fan 5 Unplugging the connector
b c
a d
6 Removing the AC fuses 7 Removing the lower mounting 8 Fastening the supports of the winch
screws
Maintenance
116
9. Open the swing-out frame: two screws on the left, two on the right.
10. Open the locking of auxiliary hinge of the swing out-frame to allow the frame to
open fully: one screw at top, one at bottom.
11. Decouple the cooling circuit inlet pipes from the module (two connectors on
bottom plate of the module): Unscrew the locking nut until fully open and pull the
pipe out.
12. Decouple the cooling circuit outlet pipes from the module (two connectors on
front plate of the module): Unscrew the locking nut until fully open and pull the
pipe out.
13. Assemble the module installation stand. See Installing the installation stand for
supply module D3 and D4 replacement on page 125. Pay attention to the width:
Select the right braces to match the width of the stand to the width of the cubicle.
14. Fasten the module installation stand to the frame of the cubicle (2 × 5 screws).
Align the stand and the rails in the cubicle on which the module lies. Adjust the
height of the feet. Note: Remove the cabinet hinge first if necessary.
WARNING! The feet must lean on a solid floor. The cubicle may topple over when
the heavy module is pulled out if the stand is not supported properly.
15. Disconnect the output busbars of the module: four busbars, one screw per
busbar.
Maintenance
117
9 Opening the swing-out 10 Opening the locking 11 Decoupling the inlet 12 Decoupling the outlet
frame
13 Assembling the stand 14 Fastening the stand 15 Disconnecting the output busbars
Maintenance
118
16. Remove the two screws that fasten the top of the module to the back of the
cabinet.
17. Install the winch: Lead the crossbeam through the left and right winch support
and the winch body. Lock the crossbeam with two locking pins.
18. Pull the module out of the cubicle onto the installation stand. Keep the pipes and
wires away from sharp edges.
WARNING! Before fastening the lifting bar, always ensure that the lifting cable is
tightly wound on the drum of the winch. A slack cable may slip, making the lifting of a
heavy module unstable. A swinging or falling module may cause damage, injury or
even death. See chapter Safety instructions for more detailed information on safe
use of the winch.
19. Fasten the lifting bar of the winch to the two module lifting holes.
20. Winch the module up.
21. Remove the module installation stand.
22. Winch the module down and lay it on a pallet.
WARNING! The module is heavy and its centre of gravity is high. The module
topples over easily. Never manoeuvre it in upright position untied. It is highly
recommended to lay the module on its side before moving the pallet.
23. Move the pallet with the module aside.

24. Install a new module in reverse order. Note: At the bottom of the module, fasten
the cooling pipes only after connecting the AC fuses. See Filling up and bleeding
the internal cooling circuit on page 131 for details on filling up the cooling circuit.
Maintenance
119
16 Removing the screws 17 Installing the winch 18 Pulling the module out
19 Fastening the lifting bar Winching the Removing the Winching the
20 21 22
module up stand module down
Maintenance
120
Inverter module R8i replacement
2. Remove the shrouds: metal grating at the upper and lower part of the cubicle
(four screws each).
3. Close the inlet (a) and outlet (b) valves of the cubicle, and drain the cooling
circuit (see Draining the internal cooling circuit on page 132. Note: Drain (d) and
bleed (c) valves have locking handles. Release the mechanism before turning.
cubicle (four bolts). Fasten the left-hand side support of the winch to the support
frame of the cubicle (four bolts). Note: Position the guide pins of the supports in
the holes of the cabinet frame before tightening the bolts. For detailed
instructions see Installing the winch on page 124.
5. Install the winch: Lead the crossbeam through the left and right winch support
and the winch body. Lock the crossbeam with two locking pins (a).
6. Open the swing out frame: two screws on the left-hand side, two on the right.
7. Open the locking of the auxiliary hinge of the swing out frame to allow the frame
to open fully: one screw on top (a), one on bottom (b).
8. Decouple the cooling circuit inlet pipe from the module: Unscrew the locking nut
until fully open and pull the pipe out.
9. Decouple the cooling circuit outlet pipe from the module: Unscrew the locking
nut until fully open and pull the pipe out.
Maintenance
121
2 Removing the shrouds 3 Draining the cooling unit 4 Fastening the supports of the winch
c
b
5 Installing the winch

a a
a d
6 Opening the swing- 7 Opening the locking 8 9 Decoupling the inlet (8) and outlet (9)
out frame
Maintenance
122
10. Unplug the fibre optic cable from the module.

11. Unplug the terminal block from the module.
12. Remove the module mounting screws (four at top, two at bottom).
13. Disconnect the DC output busbars from the module. Beware not to drop the
screws inside the module!
14. Assemble the module installation stand. See Installing the installation stand for
inverter module R8i replacement on page 126. Pay attention to the width: Select
the right braces to match the width of the stand to the width of the cubicle.
Align the stand and the rails on which the module lies on in the cubicle. Adjust
the height of the feet. Note: Remove the cabinet hinge first if necessary.
16. Fasten the lifting bar of the winch to the two module lifting holes.
WARNING! Before fastening the lifting bar, always ensure that the lifting cable is
tightly wound on the drum of the winch. A slack cable may slip, making the lifting of a
heavy module unstable. A swinging or falling module may cause damage, injury or
even death. See chapter Safety instructions for more detailed information on safe
use of the winch.
17. Pull the module out of cubicle onto the installation stand. Keep the pipes and
wires away from the sharp edges.
18. Winch the module up.
19. Remove the module installation stand.
20. Winch the module down and lay it on a pallet.
WARNING! The module is heavy and its centre of gravity is high. The module
topples over easily. Never manoeuvre it in upright position untied. It is highly
recommended to lay the module on its side before moving the pallet.
21. Move the pallet with the module aside.

22. Before installing a new module, check and service the quick connector through
which the AC output busbars or the cubicle connect to the module:
• Check the tightness of the motor cable connections at the quick connector:
70 Nm.
• Clean all contact surfaces of the quick connector and apply a layer of suitable
joint compound (e.g. Isoflex® Topas NB 52 from Klüber Lubrication) onto
them.
23. Install a new module in reverse order.
Maintenance
123
10 Unplugging the fibre optic 13 Disconnecting the 14 Fastening the 15 Pulling the module out
cables DC busbars installation stand
11 Unplugging the terminal

block
12 Removing the mounting

screws
12 12
12
12
11
10
12 12
16 Fastening the lifting 17 Winching the module 18 Removing the 19 Winching the module
bar up installation stand down
Maintenance
124
Installing the winch

cubicle (four screws). Fasten the left-hand side support of the winch to the
support frame of the cubicle (four screws). Note: Position the guide pins of the
supports in the holes of the cabinet frame before tightening the screws.
2. Lead the beam (a) through the left and right winch support and the winch body.
Lock the beam with two locking pins (b).
WARNING! Before fastening the lifting bar to the module, always ensure that the
lifting cable is tightly wound on the drum of the winch. A slack cable may slip, making
the lifting of a heavy module unstable. A swinging or falling module may cause
damage, injury or even death. See chapter Safety instructions for detailed
information on safe use of the winch.
1 2
Do not overtighten!
Max.torque 5.5 Nm.
Ensure that the studs
are in frame holes
when tightening the
screws.
Maintenance
125
Installing the installation stand for supply module D3 and D4 replacement

1. Assemble the module installation stand. Pay attention to the width: Select the
right braces to match the width of the stand to the width of the cubicle.
Slide
Brace
Do not overtighten!
Max.torque 5.5 Nm.
Ensure that the pins
are in frame holes
when tightening the
screws.
Maintenance
126
Installing the installation stand for inverter module R8i replacement

Do not overtighten screws.

Max.torque 5.5 Nm. Ensure
that the guide studs are in Brace
frame holes when fixing
screws.
Fixing of triangle support Fixing of braces
Hooks at this end of plane have

to assembly through holes in
frame cabinet.
With these threads it is possible to fix

unit to slide plate.
Do not use more than one

slide plane at a time.
These edges have to fit in

the holes in the brace.
Slide plane and support feet
Maintenance
127
Capacitors
The inverter modules employ several electrolytic capacitors. Their life span is at
least 90 000 hours depending on the operating time of the drive, loading and
ambient temperature.
It is not possible to predict 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.
Reforming
Reform (re-age) spare part capacitors once a year according to ACS 600/800
Capacitor Reforming Guide (code: 64059629 [English]), available through your local
ABB representative.
Capacitor replacement
Contact an ABB service representative.
Maintenance
128
Maintenance
129
General
The cooling system of an ACS800 liquid-cooled drive consists of two circuits: firstly,
the internal cooling circuit that covers the heat-generating electrical components and
transfers the heat to the cooling unit, and the external cooling circuit that is usually
part of a larger external cooling system. This chapter deals with the internal cooling
circuit.
Internal cooling system diagram

The following is a diagram of how the coolant circulates in the supply, inverter and
brake units of a drive system.
b d b d b d b d Coolant
OUT
A/L
Supply Inverter Inverter modules Brake

module module chopper
A/L A/L A/L A/L A/L A/L
Coolant
IN
a c a c a c a c
A/L = Air to liquid heat exchanger
The modules in each cubicle can be isolated from the main cooling circuit by closing
the inlet (a) and outlet valves (b). Each cubicle is also equipped with a drain valve (c)
and a bleed valve (d).

130
Connection to a cooling unit
Connection to an ACS800-1007LC cooling unit

Refer to the ACS800-1007LC Cooling Units User’s Manual (3AFE68621101,
English).
Connection to a custom cooling unit

General requirements
Equip the system with an expansion tank to damp pressure rise due to volume
changes when the temperature varies. Keep the pressure within the limits specified
in Specifications below. Install a pressure regulator to ensure that the maximum
permissible operating pressure is not exceeded.
The materials used in the cooling system are listed in Specifications on page 133.
Coolant temperature control
The temperature of the coolant in the internal cooling circuit must be kept within the
limits specified in Specifications on page 133. Note that the minimum temperature is
dependent on ambient temperature and relative humidity.
The following diagram shows an example of coolant temperature control using the
three-way valve in the external cooling circuit. Part of the infeed coolant flow is
directed into the return pipe through a three-way valve without letting it circulate in
heat exchanger if the coolant in the internal circuit is too cold.
Return
Heat
exchanger
Internal circuit External circuit
Bypass valve
Infeed
TC
Installation
Connect the external cooling circuit directly to the coupling flanges on the side of the
drive. Lay liquid piping with extreme care. Secure the pipes properly mechanically
and check for leaks.

131
Filling up and bleeding the internal cooling circuit

Both the drive and coolant must be at room temperature before filling in the cooling
circuit.
WARNING! Ensure that the maximum permissible operating pressure is not

exceeded. When necessary regulate the pressure to appropriate level by draining
excess coolant out of the system.
WARNING! Bleeding of the cooling circuit is very important and has to be done with
great care. Air bubbles in the cooling circuit may reduce or completely block coolant
flow and lead to overheating. Let the air out of the cooling system while filling in
coolant and, e.g. after any power module replacements.
1. Lead the bleed hoses into buckets or other suitable containers. Extend the
standard hoses when necessary.
Note: Draining propylene glycol into the sewer system is not allowed.
2. Open the bleed valves.

3. Fill the circuit with coolant. For coolant specification, see below.
4. When there is a sufficient amount of coolant in the circuit, it will begin to flow from
the bleed hoses. Let some coolant flow out before closing the bleed valves (check
that there are no bubbles visible in the bleed hose).
5. Start the coolant pump.
6. After one to two minutes, stop the pump or block the coolant flow with a valve.
7. Repeat steps 1 to 6 a few times so that all air is let out of the cooling circuit. Listen
for a humming sound and/or feel the piping for vibration to find out if there is still
air left in the circuit.
Adjustments
• Set the base pressure to 100…150 kPa by draining coolant from the fill/drain
coupling.
• Control the coolant temperature so that it stays between the limits stated under
Specifications on page 133.

132
Draining the internal cooling circuit

The internal cooling circuit can be drained through the drain valves in each cubicle.
The power modules in any cubicle can be drained without draining the whole internal
cooling circuit.
Note: Draining propylene glycol into the sewer system is not allowed.
WARNING! High-pressure warm coolant may be present in the internal cooling

circuit. No work on the cooling circuit is allowed until the pressure is lowered down
by stopping the pumps and draining coolant.
1. Lead the bleed and drain hoses into buckets or other suitable containers. Extend
the standard hoses when necessary.
2. Open the bleed valves to let air displace the liquid.
3. If required, dry the piping with compressed oil-free air of less than 6 bar.
4. If the drive is to be stored in temperatures below 0°C (32°F),
• fill the cooling circuit with a mixture of water, corrosion inhibitor and DOW
Propylene Glycol according to Freeze protection and corrosion inhibition below.
• drain the cooling circuit.

133
Specifications
Temperature limits
Ambient temperature: See chapter Technical data.
Minimum coolant inlet temperature: Condensation is not allowed. The minimum
coolant temperature to avoid condensation (at an atmospheric pressure of 1 bar) is
shown below as a function of the relative humidity (φ) and the ambient
temperature (Tair).
Tair Min. Tcoolant (°C)
(°C) φ = 95% φ = 80% φ = 65% φ = 50% φ = 40%
5 4.3 1.9 -0.9 -4.5 -7.4
10 9.2 6.7 3.7 -0.1 -3.0
15 14.2 11.5 8.4 4.6 1.5
20 19.2 16.5 13.2 9.4 6.0
25 24.1 21.4 17.9 13.8 10.5
30 29.1 26.2 22.7 18.4 15.0
35 34.1 31.1 27.4 23.0 19.4
40 39.0 35.9 32.2 27.6 23.8
45 44.0 40.8 36.8 32.1 28.2
50 49.0 45.6 41.6 36.7 32.8
55 53.9 50.4 46.3 42.2 37.1
= Not allowed as standard but he coolant temperature must be 5 °C or

above. Consult an ABB representative if operation below coolant
temperature 5 °C is required.
Example: At an air temperature of 45 °C and relative humidity of 65% the coolant
temperature may not be below +36.8 °C
Maximum coolant inlet temperature for ACS800 liquid-cooled multidrive: 38 °C

without derating of the drive output capacity. Range above 38 °C is allowed as
follows:
Range Drive output current derating Cooling arrangement
38…45 °C 1% per 1 °C temp. increase Direct cooling or cooling with optional
liquid cooling unit (ACS800-1007LC)
45…48 °C 1% per 1 °C temp. increase Direct cooling
Maximum coolant inlet temperature for ACS800 liquid-cooled wind turbine

drive: 50 °C without derating of the drive output capacity. Range above 50 °C is
allowed as follows:
Range Drive output current derating
50…55 °C 2.5% per 1 °C temp. increase
Maximum inlet temperature variation: ±4°C

Maximum temperature rise: 13°C; depends on mass flow.

134
Pressure limits
Base pressure: 100…150 kPa (recommended); 200 kPa (maximum). “Base
pressure” denotes the pressure of the system compared with the atmospheric
pressure when the cooling circuit is filled with coolant
Air counterpressure in the expansion tank: 40 kPa
Maximum design pressure: 600 kPa
Minimum pressure difference: 100 kPa / 120 kPa (hydrostatic)
Maximum pressure difference: 250 kPa
Water quality
Tap water
The use of tap water is allowed as follows. Tap water must fulfil the requirements of
the Council Directive 98/83/EC of 3/11/98 on the quality of water intended for human
consumption. Corrosion inhibition with 0.5% by volume Cortec VCI-649 is required.
pH value 6 to 9
Chloride < 50 mg/l
Sulphate < 100 mg/l
Total dissolved solids < 200 mg/l, no deposits are allowed at
the temperature of +57°C
Total hardness as CaCO3 < 250 mg/l
Conductivity < 400 µS/cm (this equals the resistance
of > 2500 ohm/cm)
The water must be clean of solid matter.
Freeze protection and corrosion inhibition

A water-glycol solution is allowed for freeze protection. Corrosion inhibition with
0.5% (vol.) Cortec VCI-649 (by Cortec Corporation, www.cortecvci.com) is required.
The glycol must be pure Dow Propylene Glycol (CAS Number: 57-55-6, available
from The Dow Chemical Company, www.dow.com).

135
Glycol concentration
This graph shows the required glycol concentration in weight percentage according
to ambient/storage temperature T.
Glycol concentration% (weight)
80
60
40
20
0 T (°C)
-50 -40 -30 -20 -10 0 +5
WARNING! Operation at temperatures below 0°C (32°F) is not permitted even with
antifreeze.
Note: If more than 25% or DOW Propylene Glycol is added, the pressure loss in the
system increases. An operating pressure of more than 150 kPa is required for
sufficient flow.
Materials
Materials used in the internal cooling circuit are:
• stainless steel AISI 316L (UNS 31603)
• heavy gauge aluminium
• plastic materials such as PA, PEX and Teflon
Note: PVC hoses are not suitable for use with antifreeze.
• rubber gasket NBR (nitrile rubber).
WARNING! If connecting external piping to the internal cooling circuit, use only
materials that are specified above. Copper and brass must not be used under any
circumstances. Even minor dissolution of copper can cause copper precipitation on
aluminium and subsequent galvanic corrosion. The liquid cooling system may not
contain any zinc (e.g. galvanized pipes) at all since zinc would react with the
inhibitor.
If the plant incorporates normal iron pipes or cast iron accessories (e.g. motor
housings), a liquid cooling unit with a heat exchanger (such as the ACS800-1007LC)
must be used to separate the systems.

136

137

This chapter contains specifications of the inputs and outputs of the RMIO board.
To which board type and revisions this chapter applies

This chapter applies to RMIO-01 board from revision J onwards and RMIO-02 board
from revision H onwards.
RMIO board specifications

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

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

Voltage 24 VDC ± 10%, short circuit proof
Maximum current 250 mA (shared between this output and optional modules installed on the RMIO)
Analogue outputs
Two programmable current outputs: 0 (4) to 20 mA, RL < 700 ohm
Resolution 0.1% (10 bit)
Inaccuracy ± 1% (Full Scale Range) at 25 °C (77°F). Temperature coefficient: ± 200 ppm/°C
(± 111 ppm/°F) max.

138
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
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 kV AC, 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), consult an ABB representative.

139
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

140

141
Technical data

This chapter contains the technical data of the ACS800-07LC.
Ratings
The ratings with 50 Hz and 60 Hz supplies are given below.
Drive type Nominal ratings No-overload Light-overload use Heavy-duty use
use
Icont.max Imax Pcontmax I2N PN I2hd Phd
A (AC) A kW A kW A kW
UN = 400 V
ACS800-07LC-0390-3 563 674 315 540 250 421 200
ACS800-07LC-0470-3 678 837 355 651 355 507 250
ACS800-07LC-0620-3 889 1037 500 853 355 665 355
ACS800-07LC-0760-3 1103 1279 630 1059 560 825 450
ACS800-07LC-0920-3 1329 1590 710 1276 710 994 500
ACS800-07LC-1210-3 1742 1994 900 1673 900 1303 710
ACS800-07LC-1370-3 1973 2347 1120 1894 1120 1476 900
ACS800-07LC-1790-3 2587 2941 1400 2484 1400 1935 1120
ACS800-07LC-2370-3 3414 3906 2000 3277 2000 2553 1400
ACS800-07LC-2940-3 4245 4858 2500 4075 2240 3175 1800
ACS800-07LC-3510-3 5067 5799 2800 4865 2800 3790 2000
UN = 500 V
ACS800-07LC-0470-5 546 673 355 524 355 408 250
ACS800-07LC-0550-5 630 838 400 605 400 471 315
ACS800-07LC-0730-5 840 1042 560 806 560 628 400
ACS800-07LC-0930-5 1070 1280 710 1027 710 800 560
ACS800-07LC-1070-5 1235 1589 900 1185 710 924 630
ACS800-07LC-1430-5 1646 1996 1120 1581 1120 1232 710
ACS800-07LC-1590-5 1833 2344 1250 1760 1250 1371 900
ACS800-07LC-2120-5 2444 2943 1600 2347 1600 1828 1250
ACS800-07LC-2790-5 3226 3885 2240 3097 2240 2413 1600
ACS800-07LC-3470-5 4011 4830 2800 3851 2800 3000 2000
ACS800-07LC-4150-5 4788 5801 3360 4596 3200 3581 2500
UN = 690 V
ACS800-07LC-0700-7 583 872 560 560 500 436 400
ACS800-07LC-0940-7 790 1182 710 759 710 591 560
ACS800-07LC-1070-7 898 1344 900 863 710 672 630
ACS800-07LC-1370-7 1143 1710 1120 1097 900 855 710
ACS800-07LC-1590-7 1334 1996 1250 1281 1250 998 900
ACS800-07LC-2030-7 1697 2538 1600 1629 1600 1269 1250
ACS800-07LC-2680-7 2239 3350 2240 2150 2000 1675 1600
ACS800-07LC-3330-7 2785 4166 2800 2673 2500 2083 2000
ACS800-07LC-3970-7 3324 4974 3200 3191 3200 2487 2500
ACS800-07LC-4630-7 3878 5802 3750 3723 3600 2901 2800
ACS800-07LC-5300-7 4432 6630 4480 4255 4200 3315 3200
ACS800-07LC-5960-7 4986 7460 5000 4787 4800 3730 3600
ACS800-07LC-6620-7 5540 8288 5600 5319 5300 4144 4200
PDM-00430970-A.6
Technical data
142
Symbols
Nominal ratings
Icont.max Continuous RMS output current. No overloadability at 40°C.
Imax Maximum output current. Allowable for 10 seconds at start, otherwise as long as allowed by drive
temperature.
Typical ratings for no-overload use
Pcont.max Typical motor power. The power ratings apply to most IEC 34 motors at nominal voltage 690 V.
Typical ratings for light-overload use (10% overloadability)
I2N Continuous rms current. 10% overload is allowed for 1 minute every 5 minutes.
PN Typical motor power. The power ratings apply to most IEC 34 motors at nominal voltage 690 V.
Typical ratings for heavy-duty use (50% overloadability)
I2hd Continuous rms current. 50% overload is allowed for 1 minute every 5 minutes.
Phd Typical motor power. The power ratings apply to most IEC 34 motors at nominal voltage 690 V.
Derating
The load capacity (current and power) decreases if the installation site altitude exceeds 1000 metres
(3281 ft), or if the ambient temperature exceeds 45 °C (104 °F).
Temperature derating
In the ambient temperature range +45°C (+113°F) to +55°C (+131°F), the rated output current is
decreased by 1% for every additional 1°C (1.8°F). The output current is calculated by multiplying the
current given in the rating table by the derating factor.
Example If the ambient temperature is 50°C (+122°F), the derating factor is 100% - 1 % · 5°C = 95%
or 0.95. The output current is then 0.95 × I or 0.95 × I . °C
2N cont.max
Altitude derating
At altitudes from 1000 to 4000 m (3281 to 13123 ft) above sea level, the derating is 0.5% for every
100 m (328 ft). For a more accurate derating, use the DriveSize PC tool.
Output frequency derating
At frequencies over 200 Hz, the derating is 0.5% for every additional 1 Hz.
Technical data
143
Auxiliary circuit current consumption

The table below shows the current consumption of the main components in the
auxiliary circuit. See also sections Arranging the external power supply for the
auxiliary circuit in chapter 69 for instructions and Connection of external power
supply for the auxiliary circuits on page 94.
Device/load Current consumption [A]
1~230 V / 50 Hz 1~230 V / 60 Hz 1~115 V / 60 Hz Note
Supply Supply Supply 1)
Diode Supply Unit and options
24 VDC power supply(U10) 0.8 0.8 1.5 -
2)
Fan of diode supply module (Y40.1) 1.3 1.6 3.2
3)
Main breaker/contactor control circuit 1.0 1.0 2.0
-
Control relays 0.5 0.5 1.0
4)
Fan in auxiliary control cubicle (Y1) 0.4 0.4 0.8
5)
Fan in incoming cubicle (Y11.1…Y14.1) 0.4 0.4 0.8
Inverter unit and options
-
24 VDC power supply (U10), and control relays 1.3 1.3 2.5
2)
Fan of inverter module (Y41.1) 0.8 1.0 2.0
Prevention of unexpected start-up circuit 0.4 0.4 0.8 6)
Brake unit
7)
Fan of chopper NBRA-658 (or -659 or -669) 0.4 0.5 1.0
8)
Fan of resistor unit 2×SAFUR200F500 2.8 3.4 6.8
Cooling unit
24 VDC power supply, and control relays See ACS800-1007LC User’s Manual
(3AFE68621101 [English]).
Notes:
1) Only with option +G304 (115 VAC control voltage)
2) There is one fan per supply or inverter module.
3) There is one control circuit per breaker (or contactor). Six-pulse supply unit has one breaker, twelve-pulse unit two, etc.
Note that the drive always supplies the breaker control circuit despite of the location of the breaker.
4) Only with option +G344.
5) Only with option +F255 or +F250. There is one fan in 400 mm wide cubicle, two fans in 600 mm and 1000 mm cubicles.
6) Only with option +Q950.
7) Only with option +D150. Number of choppers is visible in the type code, e.g. +2D150 = 2 choppers.
8) Only with option +D151. Number of choppers also define the number of resistor units. There is one resistor unit
(2×SAFUR200F500 resistors) per chopper.
Technical data
144
Type equivalence tables
Supply and inverter units

The table below shows the drive unit and inverter unit types each ACS800-07LC
consists of. Note that the supply and inverter unit types are not shown on the
nameplate of the ACS800-07LC.
Drive type Supply and inverter Supply unit type Inverter unit type
module sizes
UN = 400 V
ACS800-07LC-0390-3 1×D3 + 1×R8i ACS800-307LC-0400-3 ACS800-107LC-0390-3
UN = 500 V
UN = 690 V
PDM-00430970-A.6
Technical data
145
ACS800-07LC frame sizes and power module types

Drive type Supply modules Inverter modules
Frame sizes Qty Type Qty Type
ACS800-104LC…
UN = 400 V
ACS800-07LC-0390-3 1×D3 + 1×R8i 1 ACS800-304LC-0680-7 1 -0390-3
ACS800-07LC-0470-3 1×D3 + 1×R8i 1 ACS800-304LC-1070-7 1 -0470-3
ACS800-07LC-0620-3 1×D3 + 1×R8i 1 ACS800-304LC-1070-7 1 -0620-3
ACS800-07LC-0760-3 1×D4 + 2×R8i 1 ACS800-704LC-1370-7 2 -0390-3
ACS800-07LC-0920-3 1×D4 + 2×R8i 1 ACS800-704LC-2150-7 2 -0470-3
ACS800-07LC-1210-3 1×D4 + 2×R8i 1 ACS800-704LC-2150-7 2 -0620-3
ACS800-07LC-1370-3 2×D4 + 3×R8i 2 ACS800-704LC-1370-7 3 -0470-3
ACS800-07LC-1790-3 2×D4 + 3×R8i 2 ACS800-704LC-2150-7 3 -0620-3
ACS800-07LC-2370-3 2×D4 + 4×R8i 2 ACS800-704LC-2150-7 4 -0620-3
ACS800-07LC-2940-3 3×D4 + 5×R8i 3 ACS800-704LC-2150-7 5 -0620-3
ACS800-07LC-3510-3 3×D4 + 6×R8i 3 ACS800-704LC-2150-7 6 -0620-3
UN = 500 V
ACS800-07LC-0470-5 1×D3 + 1×R8i 1 ACS800-304LC-0680-7 1 -0470-5
ACS800-07LC-0550-5 1×D3 + 1×R8i 1 ACS800-304LC-1070-7 1 -0550-5
ACS800-07LC-0730-5 1×D3 + 1×R8i 1 ACS800-304LC-1070-7 1 -0730-5
ACS800-07LC-0930-5 1×D4 + 2×R8i 1 ACS800-704LC-1370-7 2 -0470-5
ACS800-07LC-1070-5 1×D4 + 2×R8i 1 ACS800-704LC-1370-7 2 -0550-5
ACS800-07LC-1430-5 1×D4 + 2×R8i 1 ACS800-704LC-2150-7 2 -0730-5
ACS800-07LC-1590-5 1×D4 + 3×R8i 1 ACS800-704LC-2150-7 3 -0550-5
ACS800-07LC-2120-5 2×D4 + 3×R8i 2 ACS800-704LC-2150-7 3 -0730-5
ACS800-07LC-2790-5 2×D4 + 4×R8i 2 ACS800-704LC-2150-7 4 -0730-5
ACS800-07LC-3470-5 3×D4 + 5×R8i 3 ACS800-704LC-2150-7 5 -0730-5
ACS800-07LC-4150-5 3×D4 + 6×R8i 3 ACS800-704LC-2150-7 6 -0730-5
UN = 690 V
ACS800-07LC-0700-7 1×D3 + 1×R8i 1 ACS800-304LC-0680-7 1 -0700-7
ACS800-07LC-0940-7 1×D3 + 2×R8i 1 ACS800-304LC-1070-7 2 -0480-7
ACS800-07LC-1070-7 1×D3 + 2×R8i 1 ACS800-304LC-1070-7 2 -0550-7
ACS800-07LC-1370-7 1×D4 + 2×R8i 1 ACS800-704LC-1370-7 2 -0700-7
ACS800-07LC-1590-7 1×D4 + 3×R8i 1 ACS800-704LC-2150-7 3 -0550-7
ACS800-07LC-2030-7 1×D4 + 3×R8i 1 ACS800-704LC-2150-7 3 -0700-7
ACS800-07LC-2680-7 2×D4 + 4×R8i 2 ACS800-704LC-1370-7 4 -0700-7
ACS800-07LC-3330-7 2×D4 + 5×R8i 2 ACS800-704LC-2150-7 5 -0700-7
ACS800-07LC-3970-7 2×D4 + 6×R8i 2 ACS800-704LC-2150-7 6 -0700-7
ACS800-07LC-4630-7 3×D4 + 7×R8i 3 ACS800-704LC-2150-7 7 -0700-7
ACS800-07LC-5300-7 3×D4 + 8×R8i 3 ACS800-704LC-2150-7 8 -0700-7
ACS800-07LC-5960-7 3×D4 + 9×R8i 3 ACS800-704LC-2150-7 9 -0700-7
ACS800-07LC-6620-7 3×D4 + 10×R8i 3 ACS800-704LC-2150-7 10 -0700-7
PDM-00430970-A.6
Dimensions and weight

See chapter Dimensions and weights.
Technical data
146
Losses and cooling circuit data

Drive type Losses Cooling media
Ploss Liquid Qty Massflow Pressure
loss
kW l l/min. kPa
UN = 400 V
ACS800-07LC-0390-3 8.7 6.5 32 100
ACS800-07LC-0470-3 10.5 6.5 32 100
ACS800-07LC-0620-3 14.1 6.5 32 100
ACS800-07LC-0760-3 16.3 8 45 100
ACS800-07LC-0920-3 20.9 8 45 100
ACS800-07LC-1210-3 26.4 8 45 100
ACS800-07LC-1370-3 28.0 14 77 100
ACS800-07LC-1790-3 37.4 14 77 100
ACS800-07LC-2370-3 51.3 16 90 100
ACS800-07LC-2940-3 61.9 22 122 100
ACS800-07LC-3510-3 75.8 24 135 100
UN = 500 V
ACS800-07LC-0470-5 8.7 6.5 32 100
ACS800-07LC-0550-5 10.0 6.5 32 100
ACS800-07LC-0730-5 13.4 6.5 32 100
ACS800-07LC-0930-5 16.2 8 45 100
ACS800-07LC-1070-5 19.4 8 45 100
ACS800-07LC-1430-5 25.3 8 45 100
ACS800-07LC-1590-5 29.4 10 58 100
ACS800-07LC-2120-5 36.1 14 77 100
ACS800-07LC-2790-5 49.2 16 90 100
ACS800-07LC-3470-5 59.6 22 122 100
ACS800-07LC-4150-5 72.7 24 135 100
UN = 690 V
ACS800-07LC-0700-7 11.8 6.5 32 100
ACS800-07LC-0940-7 16.7 8 45 100
ACS800-07LC-1070-7 19.0 8 45 100
ACS800-07LC-1370-7 22.5 8 45 100
ACS800-07LC-1590-7 28.0 10 58 100
ACS800-07LC-2030-7 34.0 10 58 100
ACS800-07LC-2680-7 44.2 16 90 100
ACS800-07LC-3330-7 54.7 22 103 100
ACS800-07LC-3970-7 66.2 20 116 100
ACS800-07LC-4630-7 75.8 26 148 100
ACS800-07LC-5300-7 87.4 28 161 100
ACS800-07LC-5960-7 99.3 30 174 100
ACS800-07LC-6620-7 111.7 32 187 100
PDM-00430970-C.4
Ploss coolant is 98% and Ploss air is 2%.
Technical data
147
Supply unit AC and DC fuses

All fuses are UL recognized.
Diode Supply Unit type Basic DSU module type AC fuses DC fuses
Frame Type Code1) Qty Type Code1) Qty
UN = 400 V (Range 380 - 415 V)
6-pulse diode supply
ACS800-307LC-0400-3 ACS800-304LC-0680-7 D3 170M6263 68653215 3 170M5496 68653240 4
ACS800-307LC-0620-3 ACS800-304LC-1070-7 D3 170M6267 68636540 3 170M5499 68636531 4
ACS800-307LC-0790-3 ACS800-704LC-1370-7 D4 170M6263 68653215 6 170M5496 68653240 8
ACS800-307LC-1240-3 ACS800-704LC-2150-7 D4 170M6267 68636540 6 170M5499 68636531 8
ACS800-307LC-1470-3 ACS800-704LC-1370-7 2×D4 170M6263 68653215 12 170M5496 68653240 16
ACS800-307LC-2220-3 ACS800-704LC-2150-7 2×D4 170M6267 68636540 12 170M5499 68636531 16
ACS800-307LC-3460-3 ACS800-704LC-2150-7 3×D4 170M6267 68636540 18 170M5499 68636531 24
ACS800-507LC-0790-3 ACS800-704LC-1370-7 D4 170M6263 68653215 6 170M5496 68653240 8
ACS800-507LC-1240-3 ACS800-704LC-2150-7 D4 170M6267 68636540 6 170M5499 68636531 8
ACS800-507LC-1470-3 ACS800-704LC-1370-7 2×D4 170M6263 68653215 12 170M5496 68653240 16
ACS800-507LC-2220-3 ACS800-704LC-2150-7 2×D4 170M6267 68636540 12 170M5499 68636531 16
ACS800-507LC-3460-3 ACS800-704LC-2150-7 3×D4 170M6267 68636540 18 170M5499 68636531 24
ACS800-1107LC-1100-3 ACS800-304LC-0680-7 + D3+ 170M6263 68653215 9 170M5496 68653240 12
ACS800-704LC-1370-7 D4
ACS800-1107LC-1740-3 ACS800-304LC-1070-7 + D3+ 170M6267 68636540 9 170M5499 68636531 12
ACS800-704LC-2150-7 D4
ACS800-1107LC-2210-3 ACS800-704LC-1370-7 3×D4 170M6263 68653215 18 170M5496 68653240 24
ACS800-1107LC-3460-3 ACS800-704LC-2150-7 3×D4 170M6267 68636540 18 170M5499 68636531 24
ACS800-1207LC-1470-3 ACS800-704LC-1370-7 2×D4 170M6263 68653215 12 170M5496 68653240 16
ACS800-1207LC-2220-3 ACS800-704LC-2150-7 2×D4 170M6267 68636540 12 170M5499 68636531 16
UN = 500 V (Range 380 - 500 V)
ACS800-307LC-0490-5 ACS800-304LC-0680-7 D3 170M6263 68653215 3 170M5496 68653240 4
ACS800-307LC-0780-5 ACS800-304LC-1070-7 D3 170M6267 68636540 3 170M5499 68636531 4
ACS800-307LC-0990-5 ACS800-704LC-1370-7 D4 170M6263 68653215 6 170M5496 68653240 8
ACS800-307LC-1560-5 ACS800-704LC-2150-7 D4 170M6267 68636540 6 170M5499 68636531 8
ACS800-307LC-1840-5 ACS800-704LC-1370-7 2×D4 170M6263 68653215 12 170M5496 68653240 16
ACS800-307LC-2770-5 ACS800-704LC-2150-7 2×D4 170M6267 68636540 12 170M5499 68636531 16
ACS800-307LC-4330-5 ACS800-704LC-2150-7 3×D4 170M6267 68636540 18 170M5499 68636531 24
ACS800-507LC-0990-5 ACS800-704LC-1370-7 D4 170M6263 68653215 6 170M5496 68653240 8
ACS800-507LC-1560-5 ACS800-704LC-2150-7 D4 170M6267 68636540 6 170M5499 68636531 8
ACS800-507LC-1840-5 ACS800-704LC-1370-7 2×D4 170M6263 68653215 12 170M5496 68653240 16
ACS800-507LC-2770-5 ACS800-704LC-2150-7 2×D4 170M6267 68636540 12 170M5499 68636531 16
ACS800-507LC-4330-5 ACS800-704LC-2150-7 3×D4 170M6267 68636540 18 170M5499 68636531 24
ACS800-1107LC-1380-5 ACS800-304LC-0680-7 + D3+ 170M6263 68653215 9 170M5496 68653240 12
ACS800-704LC-1370-7 D4
ACS800-1107LC-2170-5 ACS800-304LC-1070-7 + D3+ 170M6267 68636540 9 170M5499 68636531 12
ACS800-704LC-2150-7 D4
ACS800-1107LC-2760-5 ACS800-704LC-1370-7 3×D4 170M6263 68653215 18 170M5496 68653240 24
ACS800-1107LC-4330-5 ACS800-704LC-2150-7 3×D4 170M6267 68636540 18 170M5499 68636531 24
ACS800-1207LC-1840-5 ACS800-704LC-1370-7 2×D4 170M6263 68653215 12 170M5496 68653240 16
ACS800-1207LC-2770-5 ACS800-704LC-2150-7 2×D4 170M6267 68636540 12 170M5499 68636531 16
UN = 690 V (Range 525 - 690 V)
ACS800-307LC-0680-7 ACS800-304LC-0680-7 D3 170M6263 68653215 3 170M5496 68653240 4
ACS800-307LC-1070-7 ACS800-304LC-1070-7 D3 170M6267 68636540 3 170M5499 68636531 4
ACS800-307LC-1370-7 ACS800-704LC-1370-7 D4 170M6263 68653215 6 170M5496 68653240 8
ACS800-307LC-2150-7 ACS800-704LC-2150-7 D4 170M6267 68636540 6 170M5499 68636531 8
Technical data
148
Diode Supply Unit type Basic DSU module type AC fuses DC fuses
Frame Type Code1) Qty Type Code1) Qty
ACS800-307LC-2540-7 ACS800-704LC-1370-7 2×D4 170M6263 68653215 12 170M5496 68653240 16
ACS800-307LC-3820-7 ACS800-704LC-2150-7 2×D4 170M6267 68636540 12 170M5499 68636531 16
ACS800-307LC-5980-7 ACS800-704LC-2150-7 3×D4 170M6267 68636540 18 170M5499 68636531 24
ACS800-507LC-1370-7 ACS800-704LC-1370-7 D4 170M6263 68653215 6 170M5496 68653240 8
ACS800-507LC-2150-7 ACS800-704LC-2150-7 D4 170M6267 68636540 6 170M5499 68636531 8
ACS800-507LC-2540-7 ACS800-704LC-1370-7 2×D4 170M6263 68653215 12 170M5496 68653240 16
ACS800-507LC-3820-7 ACS800-704LC-2150-7 2×D4 170M6267 68636540 12 170M5499 68636531 16
ACS800-507LC-5980-7 ACS800-704LC-2150-7 3×D4 170M6267 68636540 18 170M5499 68636531 24
18-pulse diode (supply)
ACS800-1107LC-1910-7 ACS800-304LC-0680-7 + D3+ 170M6263 68653215 9 170M5496 68653240 12
ACS800-704LC-1370-7 D4
ACS800-1107LC-2990-7 ACS800-304LC-1070-7 + D3+ 170M6267 68636540 9 170M5499 68636531 12
ACS800-704LC-2150-7 D4
ACS800-1107LC-3810-7 ACS800-704LC-1370-7 3×D4 170M6263 68653215 18 170M5496 68653240 24
ACS800-1107LC-5980-7 ACS800-704LC-2150-7 3×D4 170M6267 68636540 18 170M5499 68636531 24
ACS800-1207LC-2540-7 ACS800-704LC-1370-7 2×D4 170M6263 68653215 12 170M5496 68653240 16
ACS800-1207LC-3820-7 ACS800-704LC-2150-7 2×D4 170M6267 68636540 12 170M5499 68636531 16
PDM-00430970.xls-A.25
1)
ABB factory code
Technical data
149
Inverter unit DC fuses

Inverter unit type Basic module type DC fuses
Frame Type (by Bussmann) Code1) Qty
UN = 400 V
ACS800-107LC-0390-3 ACS800-104LC-0390-3 R8i 170M6415 68731658 2
ACS800-107LC-0470-3 ACS800-104LC-0470-3 R8i 170M6415 68731658 2
ACS800-107LC-0620-3 ACS800-104LC-0620-3 R8i 170M6419 68393108 2
ACS800-107LC-0760-3 ACS800-104LC-0390-3 2×R8i 170M6415 68731658 4
ACS800-107LC-0920-3 ACS800-104LC-0470-3 2×R8i 170M6415 68731658 4
ACS800-107LC-1210-3 ACS800-104LC-0620-3 2×R8i 170M6419 68393108 4
ACS800-107LC-1370-3 ACS800-104LC-0470-3 3×R8i 170M6415 68731658 6
ACS800-107LC-1790-3 ACS800-104LC-0620-3 3×R8i 170M6419 68393108 6
ACS800-107LC-2370-3 ACS800-104LC-0620-3 4×R8i 170M6419 68393108 8
ACS800-107LC-2940-3 ACS800-104LC-0620-3 5×R8i 170M6419 68393108 10
ACS800-107LC-3510-3 ACS800-104LC-0620-3 6×R8i 170M6419 68393108 12
UN = 500 V
ACS800-107LC-0470-5 ACS800-104LC-0470-5 R8i 170M6415 68731658 2
ACS800-107LC-0550-5 ACS800-104LC-0550-5 R8i 170M6415 68731658 2
ACS800-107LC-0730-5 ACS800-104LC-0730-5 R8i 170M6419 68393108 2
ACS800-107LC-0930-5 ACS800-104LC-0470-5 2×R8i 170M6415 68731658 4
ACS800-107LC-1070-5 ACS800-104LC-0550-5 2×R8i 170M6415 68731658 4
ACS800-107LC-1430-5 ACS800-104LC-0730-5 2×R8i 170M6419 68393108 4
ACS800-107LC-1590-5 ACS800-104LC-0550-5 3×R8i 170M6415 68731658 6
ACS800-107LC-2120-5 ACS800-104LC-0730-5 3×R8i 170M6419 68393108 6
ACS800-107LC-2790-5 ACS800-104LC-0730-5 4×R8i 170M6419 68393108 8
ACS800-107LC-3470-5 ACS800-104LC-0730-5 5×R8i 170M6419 68393108 10
ACS800-107LC-4150-5 ACS800-104LC-0730-5 6×R8i 170M6419 68393108 12
UN = 690 V
ACS800-107LC-0700-7 ACS800-104LC-0700-7 R8i 170M65492) 68736021 2
ACS800-107LC-0940-7 ACS800-104LC-0480-7 2×R8i 170M6545 68735980 4
ACS800-107LC-1070-7 ACS800-104LC-0550-7 2×R8i 170M6546 68736005 4
ACS800-107LC-1370-7 ACS800-104LC-0700-7 2×R8i 170M65492) 68736021 4
ACS800-107LC-1590-7 ACS800-104LC-0550-7 3×R8i 170M6546 68736005 6
ACS800-107LC-2030-7 ACS800-104LC-0700-7 3×R8i 170M65492) 68736021 6
ACS800-107LC-2680-7 ACS800-104LC-0700-7 4×R8i 170M65492) 68736021 8
ACS800-107LC-3330-7 ACS800-104LC-0700-7 5×R8i 170M65492) 68736021 10
ACS800-107LC-3970-7 ACS800-104LC-0700-7 6×R8i 170M65492) 68736021 12
ACS800-107LC-4630-7 ACS800-104LC-0700-7 7×R8i 170M65492) 68736021 14
ACS800-107LC-5300-7 ACS800-104LC-0700-7 8×R81 170M65492) 68736021 16
ACS800-107LC-5960-7 ACS800-104LC-0700-7 9×R8i 170M65492) 68736021 18
ACS800-107LC-6620-7 ACS800-104LC-0700-7 10×R8i 170M65492) 68736021 20
PDM-00430970.xls - A.25
1) ABB factory code
2)
The drives with UL marking have UL recognized fuses instead (10URD73TTF1100 by Ferraz Shawmut)
Technical data
150
Input busbar and lead-through data

The data is divided into subsections according to number and size of supply
modules used. For the usage of modules in each drive type, see the section Ratings
on page 141.
Units without built-in main breaker or contactor (no option +F250 or +F255)
The cables enter the supply module cubicle(s). Each supply module is installed in a
cubicle of its own.
Supply No. of busbars Tightening Cable lead-

Screw size
modules 6-pulse unit 12-pulse unit torque throughs
1×D3 3 - 70 Nm 12 × Ø60 mm
M12 (½”)
1×D4 2×3 2×3 (50 lb.ft) (2.36“)
70 Nm 2 × (12 ×
2×D4 2×(2×3) 2×(2×3) M12 (½”)
(50 lb.ft) Ø60 mm)
70 Nm 3 × (12 ×
3×D4 3×(2×3) 3×(2×3) M12 (½”)
(50 lb.ft) Ø60 mm)
Dimensions of input
busbar in
supply module cubicle
Technical data
151
Units with built-in main breaker (option +F255)

The cables enter the breaker cubicle. In a 12-pulse unit, there are two breakers and
breaker cubicles.

Screw size
1×D3 2×31) -
18 × Ø60 mm
1×D4 2×31) 2×(2×3)1) M12 (½”) 70 Nm (50 lb.ft)
(2.36“)
2×D4 3×31) 2×(2×3)1)
2 × (18 ×
3×D4 2×(3×3)1) M12 (½") 70 Nm (50 lb.ft)
Ø60 mm)
3×32) M12 (½") 70 Nm (50 lb.ft) 27 × Ø60 mm
1) Dimensions of input terminal in 2) Dimensions of input busbar in

600 mm breaker cubicle 1000 mm breaker cubicle
Units with built-in main contactor (option +F250)

The cables enter the contactor cubicle. In a 12-pulse unit, there are two contactors
and contactor cubicles.

Screw size
6 × Ø60 mm
Any 3 2×3 M12 (½") 70 Nm (50 lb.ft)
(2.36“)
Dimensions of input busbar in

400 mm contactor cubicle
Technical data
152
Motor cable busbar and lead-through data

The data is divided into subsections according to number and size of inverter
modules used. For the usage of modules in each drive type, see Ratings on
page 141.
Units without the Common Motor Terminal cubicle (no option +H359)
When the drive is not equipped with the Common Motor Terminal (CMT) cubicle, the
motor cables enter the inverter module cubicle(s).
Inverter unit Tightening Cable lead-
No. of busbars Screw size
configuration torque throughs
n × [6 × Ø60 mm
n×R8i n×3 M12 (½”) 70 Nm (50 lb.ft)
(2.36“)]
Dimensions of output busbar in

inverter module cubicle
n = number of inverter modules
Technical data
153
Units with the Common Motor Terminal (CMT) cubicle (option +H359)
Inverter unit
CMT cubicle No. of Tightening
ACS800-07LC Screw size Cable lead-throughs
Modules width [mm] busbars torque
type
R8i…2×R8i All 300 3
-1370-3, 1590-5, M12 (½”) 70 Nm (50 lb.ft) 9 × Ø60 mm (2.36“)
3×R8i 300 3
1590-7, 2030-7
3×R8i -1790-3, 2120-5 400 3
M12 (½”) 70 Nm (50 lb.ft) 12 × Ø60 mm
4×R8i, 5×R8i 690 V 400 3
4×R8i 400 and 500 V 600 2×3 M12 (½”) 70 Nm (50 lb.ft) 18 × Ø60 mm
5×R8i, 6×R8i 400 and 500 V 2×400 2×3 M12 (½”) 70 Nm (50 lb.ft) 2 × (12 × Ø60 mm)
6×R8i, 7×R8i 690 V 600 2×3 M12 (½”) 70 Nm (50 lb.ft) 18 × Ø60 mm
8×R8i, 9×R8i 690 V 2×400 2×3 M12 (½”) 70 Nm (50 lb.ft) 2 × (12 × Ø60 mm)
12 × Ø60 mm +
10×R8i 690 V 400+600 3+(2×3) M12 (½”) 70 Nm (50 lb.ft)
18 × Ø60 mm
Dimensions of output busbar in 300 mm

CMT cubicle
Dimensions of output busbar in Dimensions of output busbar in

400 mm CMT cubicle 600 mm CMT cubicle
Technical data
154
Input power connection

Voltage (U1) 380/400/415 VAC 3-phase ± 10% for 400 VAC units
380/400/415/440/460/480/500 VAC 3-phase ± 10% for 500 VAC units
525/550/575/600/660/690 VAC 3-phase ± 10% for 690 VAC units
Prospective short-circuit Units without earthing/grounding switch:
current (IEC 60439-1, Icf
UL508C)
65 kA
Units with earthing/grounding switch:
Icw / 1 s Ipk
50 kA 105 kA
US/Canada: The drive is suitable for use in a circuit capable of delivering not more than
65,000 A rms symmetrical at 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
Fundamental power factor 0.98 (at nominal load)
(cos phi1)
Input power cable lead- See Input busbar and lead-through data on page 150.
throughs
Input busbars at each supply See Input busbar and lead-through data on page 150.
module
Transformer for a 12-, 18- and 24 -pulse supply
According to IEC60076-1 (1993+A1:1999).
Connection Dy 11 d0 or Dyn 11 d0 (12-pulse supply). For 18- and 24-pulse supply, please consult the
transformer manufacturer.
Phase shift between 30° electrical (12-pulse supply) or 20° (18-pulse supply) or 15° (24-pulse supply)
secondaries
Voltage difference between < 0.5%
secondaries
Short-circuit impedance of > 5%
secondaries
Short-circuit impedance < 10% of the percentage impedance
difference between
secondaries
No grounding of the secondaries allowed. Static shield recommended.
Technical data
155
Motor connection
Voltage (U2) 0 to U1, 3-phase symmetrical, Umax at the field weakening point
Frequency DTC mode: 0 to 3.2 × fFWP. Maximum frequency 300 Hz.
UNmains
fFWP = · fNmotor
UNmotor
where fFWP = frequency at field weakening point; UNmains = mains (input power) voltage;
UNmotor = rated motor voltage; fNmotor = rated motor frequency
Frequency resolution 0.01 Hz
Current See Ratings on page 141.
Power limit 2 × Phd. After approximately 2 minutes at 2 × Phd, the limit is set at Pcont.max.
Field weakening point 8 to 300 Hz
Switching frequency 2 kHz (average)
Motor cable lead-throughs Units without the Common Motor Terminal cubicle: TO BE ADDED
Units with the Common Motor Terminal cubicle: TO BE ADDED
Maximum recommended 100 m (328 ft). Motor cables up to 500 m (1640 ft) long are allowed but then the
motor cable length installation does not fulfil category C2 or C3 of the EMC product standard. See section CE
marking.
Efficiency
Approximately 98% at nominal power level
Cooling
Method Liquid cooling.
Degrees of protection
IP42; IP54
Ambient conditions
Environmental limits for the drive are given below. The drive must be used in a heated,
indoor controlled environment.
Operation Storage Transportation
installed for stationary use in the protective package in the protective package
Installation site altitude 0 to 4000 m (13123 ft) above - -
sea level [above 1000 m
(3281 ft), see Derating on
page 142]
Air temperature 0…+55° (+32…+131°F) -40…+70°C (-40 to +158°F) -40…+70°C (-40 to +158°F)
[above +45°C (+113°F), see
Derating on page 142]
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.
(IEC60721-3-3, IEC60721-3-2, Boards with coating: Boards with coating: Boards with coating:
IEC60721-3-1) 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
Technical data
156
Vibration Marine requirements 1M2, IEC 60721-3-1 2M2, IEC 60721-3-2

±1 mm (peak value, 1.5 mm (2…9 Hz) 3,5 mm (2…9 Hz)
2…13.2 Hz) 5 m/s2 (9…200 Hz) 10 m/s2 (9…200 Hz)
0.7g (13.2 - 100 Hz) Random 10-200 Hz,
Max. amplification 10 acceleration density 1 m2/s³
IEC 60068-2-6
0,075 mm (0…58 Hz)
10 m/s2 (58…150Hz)
Max. amplification 10
Shock (IEC 60068-2-29) Not allowed Max. 100 m/s2 (330 ft./s2), Max. 100 m/s2 (330 ft./s2),
11 ms 11 ms
Free fall Not allowed 100 mm (4 in.) for weight 100 mm (4 in.) for weight
over 100 kg (220 lb.) over 100 kg (220 lb.)
Materials
Cabinet Hot-dip zinc-coated (thickness approx. 20 µm) steel sheet (thickness 1.5 mm) with
polyester thermosetting powder coating (thickness approx. 80 µm) on visible surfaces
except back panel. Colour: RAL 7035 (light beige, semigloss).
Busbars Tin- or silver-plated copper
Internal cooling circuit piping Aluminium, acid-fast stainless steel, PA pipes
Fire safety of materials Insulating materials and non-metallic items: Mostly self-extinctive
(IEC 60332-1)
Packaging Frame: Wood or plywood. Plastic wrapping: PE-LD. Bands: PP or steel.
Disposal The drive contains raw materials that should be recycled to preserve energy and natural
resources. The package materials are environmentally compatible and recyclable. All
metal parts can be recycled. The plastic parts can either be recycled or burned under
controlled circumstances, according to local regulations. Most recyclable parts are marked
with recycling marks.
If recycling is not feasible, all parts excluding electrolytic capacitors and printed circuit
boards can be landfilled. The DC capacitors (C1-1 to C1-x) contain electrolyte and the
printed circuit boards contain lead, both of which are classified as hazardous waste within
the EU. They must be removed and handled according to local regulations.
For further information on environmental aspects and more detailed recycling instructions,
please contact your local ABB distributor.
Internal cooling circuit data

See chapter The internal cooling circuit
Tightening torques for power connections

Screw size Torque
M5 3.5 Nm (2.6 lbf.ft)
M6 9 Nm (6.6 lbf.ft)
M8 20 Nm (14.8 lbf.ft)
M10 40 Nm (29.5 lbf.ft)
M12 70 Nm (52 lbf.ft)
M16 180 Nm (133 lbf.ft)
Technical data
157
Applicable standards
The drive complies with the following standards.
• 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 (IEC 529) Degrees of protection provided by enclosures (IP code).
• IEC 60664-1 (1992) Insulation coordination for equipment within low-voltage systems. Part 1: Principles,
requirements and tests.
• EN 61800-3 (2004) EMC product standard including specific test methods
• EN 61800-5-1 Adjustable speed electrical power drive systems - Part 5-1: safety requirements
• UL 508A UL Standard for Safety, Power Conversion Equipment, second edition
• CSA C22.2 No. 14-95 Industrial control equipment
Technical data
158
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).
Compliance with the European Low Voltage Directive

The compliance with the European Low Voltage Directive has been verified according to standards
EN 50178, EN 61800-5-1 and EN 60204-1.
Compliance with the European EMC Directive

The compliance of ACS800-07LC with the European EMC Directive has been verified according to the
EMC product standard (EN 61800-3 [2004]) as described in Compliance with the EN 61800-3 (2004),
category C2; Compliance with the EN 61800-3 (2004), category C3 and Compliance with the EN
61800-3 (2004), category C4 below.
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 domestic premises. It also includes establishments directly connected
without intermediate transformers to a low-voltage power supply network which supplies buildings used
for domestic purposes.
Second environment includes all establishments other than those directly connected to a low-voltage
power supply network which supplies buildings used for domestic purposes
Drive of category C2. PDS of rated voltage less than 1000 V, which is neither a plug in device nor a
movable device and, when used in the first environment, is intended to be installed and commissioned
only by a professional.
Drive of category C3. PDS of rated voltage less than 1000 V, intended for use in the second
environment and not intended for use in the first environment.
Drive of category C4. PDS of rated voltage equal to or above 1000 V, or rated current equal to or above
400 A, or intended for use in complex systems in the second environment.
Compliance with the EN 61800-3 (2004), category C2
The 400 and 500 V drives meet the requirements of the EMC Directive as follows:
1. The supply unit is equipped with EMC filter +E202.
2. The motor and control cables are selected as specified in chapter Planning the electrical installation.
3. The drive is installed according to the instructions given in chapter Electrical installation.
4. Motor cables do not exceed 100 metres (328 ft).
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
159
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.

The drive meets the requirements of the EMC Directive as follows:
3. Motor cables do not exceed 100 metres (328 ft).
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 natural suppression in transformers and cables is sufficient. If in doubt, the supply
transformer with static screening between the primary and secondary windings can be used.
Medium voltage network

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

Equipment
Drive
(victim)
Equipment Equipment
2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available
from the local ABB representative.
Compliance with the Machinery Directive

The drive is intended to be incorporated into machinery to constitute machinery covered by Machinery
Directive (98/37/EC) and does therefor not in every respect comply with the provisions of the directive.
For more information see the Declaration of Incorporation by ABB Drives (code 64652770).
Technical data
160
UL and CSA markings

UL and CSA markings are pending as follows:
The drive is cULus listed and cCSAus certified. The approvals are valid with rated
voltages up to 600 V. The markings are attached to the drives when options +C129
(cULus) or +C134 (cCSAus) are selected.
UL and CSA notes

Input power connection – Prospective short-circuit current (IEC 60439-1) is 65 kA (Icf). The drive is
suitable for use in a circuit capable of delivering not more than 65,000 symmetrical amperes (rms) at
600 V maximum when protected with the fuses given in Supply unit AC and DC fuses on page 147.
Disconnecting device (disconnecting means) – See chapter Planning the electrical installation,
page 55.
Ambient conditions – The drive is to be used in a heated indoor controlled environment. For the
specifications, see Ambient conditions on page 155.
Input cable fuses – For installation in the United States, branch circuit protection must be provided in
accordance with National Electric Code (NEC) and any applicable local codes. To fulfil this requirement,
use the US fuses given in Supply unit AC and DC fuses on page 147.
For installation in Canada, branch circuit protection must be provided in accordance with Canada Elec-
tric Code and any applicable provincial codes. To fulfil this requirement, use the UL classified fuses
given in Supply unit AC and DC fuses on page 147.
Power cable selection – See chapter Planning the electrical installation, page 72.
Power cable connections – For the connection diagram and tightening torques, see Electrical
installation.
Control connections – For the connection diagram and tightening torques, see Electrical installation.
Overload protection – 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.
Brake unit – The drive can be equipped with a brake unit that will allow the drive to dissipate
regenerative energy (normally associated with quickly decelerating a motor).
UL standards – See Applicable standards on page 157.
Patent protection in the USA

This product is protected by one or more of the following US patents
4,920,306 5,301,085 5,463,302 5,521,483 5,532,568 5,589,754
5,654,624 5,799,805 5,940,286 5,942,874 5,952,613 6,094,364
6,147,887 6,175,256 6,184,740 6,195,274 6,229,356 6,252,436
6,265,724 6,305,464 6,313,599 6,316,896 6,335,607 6,370,049
6,396,236 6,448,735 6,498,452 6,552,510 6,597,148 6,741,059
6,774,758 6,844,794 6,856,502 6,859,374 6,922,883 6,940,253
6,934,169 6,956,352 6,958,923 6,967,453 6,972,976 6,977,449
6,984,958 6,985,371 6,992,908 6,999,329 7,023,160 7,034,510
7,036,223 7,045,987 D503,931 D510,319 D510,320 D511,137
D511,150 D512,026 D512,696
Other patents are pending.
Technical data
161
Free Free
Height Depth Width 1 space space on Weight
Drive type Frame
above 1) side 2)
[mm] [mm] [mm] [mm] [mm] kg
UN=400 V
ACS800-07LC-0390-3 1×D3+1×R8i 2003 644 730 400 270 700
ACS800-07LC-0470-3 1×D3+1×R8i 2003 644 730 400 270 700
ACS800-07LC-0620-3 1×D3+1×R8i 2003 644 730 400 270 700
ACS800-07LC-0760-3 1×D4+2×R8i 2003 644 930 400 270 870
ACS800-07LC-0920-3 1×D4+2×R8i 2003 644 930 400 270 870
ACS800-07LC-1210-3 1×D4+2×R8i 2003 644 930 400 270 870
ACS800-07LC-1370-3 2×D4+3×R8i 2003 644 1530 400 270 1040
ACS800-07LC-1790-3 2×D4+3×R8i 2003 644 1530 400 270 1440
ACS800-07LC-2370-3 2×D4+4×R8i 2003 644 1830 400 270 1660
ACS800-07LC-2940-3 3×D4+5×R8i 2003 644 2430 400 270 1910
ACS800-07LC-3510-3 3×D4+6×R8i 2003 644 2630 400 270 2080
UN=500 V
ACS800-07LC-0470-5 1×D3+1×R8i 2003 644 730 400 270 700
ACS800-07LC-0550-5 1×D3+1×R8i 2003 644 730 400 270 700
ACS800-07LC-0730-5 1×D3+1×R8i 2003 644 730 400 270 700
ACS800-07LC-0930-5 1×D4+2×R8i 2003 644 930 400 270 870
ACS800-07LC-1070-5 1×D4+2×R8i 2003 644 930 400 270 870
ACS800-07LC-1430-5 1×D4+2×R8i 2003 644 930 400 270 870
ACS800-07LC-1590-5 1×D4+3×R8i 2003 644 1130 400 270 1040
ACS800-07LC-2120-5 2×D4+3×R8i 2003 644 1530 400 270 1440
ACS800-07LC-2790-5 2×D4+4×R8i 2003 644 1830 400 270 1660
ACS800-07LC-3470-5 3×D4+5×R8i 2003 644 2430 400 270 1910
ACS800-07LC-4150-5 3×D4+6×R8i 2003 644 2630 400 270 1080
UN=690 V
ACS800-07LC-0700-7 1×D3+1×R8i 2003 644 730 400 270 700
ACS800-07LC-0940-7 1×D3+2×R8i 2003 644 930 400 270 830
ACS800-07LC-1070-7 1×D3+2×R8i 2003 644 930 400 270 830
ACS800-07LC-1370-7 1×D4+2×R8i 2003 644 930 400 270 870
ACS800-07LC-1590-7 1×D4+3×R8i 2003 644 1130 400 270 1040
ACS800-07LC-2030-7 1×D4+3×R8i 2003 644 1130 400 270 1040
ACS800-07LC-2680-7 2×D4+4×R8i 2003 644 1830 400 270 1660
ACS800-07LC-3330-7 2×D4+5×R8i 2003 644 2030 400 270 1910
ACS800-07LC-3970-7 2×D4+6×R8i 2003 644 2230 400 270 2080
ACS800-07LC-4630-7 3×D4+7×R8i 2003 644 2930 400 270 2780
ACS800-07LC-5300-7 3×D4+8×R8i 2003 644 3130 400 270 2950
ACS800-07LC-5960-7 3×D4+9×R8i 2003 644 3330 400 270 3120
ACS800-07LC-6620-7 3×D4+10×R8i 2003 644 3630 400 270 3400
PDM-00430970-A.6
1) Free space above to allow opening of pressure relief vents (that open automatically upon arc fault)
2) Free space on the hinge side of the cabinet. Extra space is needed to make the door open fully when the
converter module is being pulled out of the cubicle.
Depth Depth excluding the door equipment (switches, handles, etc.).
Width 1 Basic unit with no options (6- or 12-pulse supply, no main breaker, no RFI filter +E202, no common
output terminals). For more information, see Cubicle widths and positions in cabinet line-ups on page
162.
Weight Weight of basic unit (no options) with an empty cooling circuit

162
Cubicle widths and positions in cabinet line-ups

Seen from the front, the drive consists of the following units from left to right:
• diode supply unit
• inverter unit
• brake unit (optional)
• liquid-cooling unit (optional).
The data is divided into subsections accordingly later in this chapter.
Cubicle widths and positions in the supply unit

The table below shows the supply unit cubicle widths in millimetres and the position
(index) in the supply unit line-up. See Cubicle widths and positions in cabinet line-
ups on page 162 for the supply modules and supply units used in each ACS800-
07LC.
Cubicle Supply Width Index Cubicle Supply Width Index
modules modules
6-pulse configuration 12-pulse configuration (option +A004)
1×D3 units 0400-3, 0490-5, 0680-7 1×D4 units 0790-3, 0990-5, 1370-7
ICU1 - 400 20 ICU1 - 400 20
RFI1 - 300 25 DSU1* D4 400 30
DSU1* D3 400 30 ICU2 - 400 60
1×D3 units 0620-3, 0780-5, 1070-7 1×D4 units 1240-3, 1560-5, 2150-7
ICU1 - 600 20 ICU1 - 600 20
RFI1 - 300 25 DSU1* D4 400 30
DSU1* D3 400 30 ICU2 - 600 60
1×D4 2×D4
ICU1 - 600 20 ICU1 - 600 20
DSU1* D4 400 30 DSU1* D4 400 30
2×D4 DSU2 D4 400 40
DSU1* D4 400 10 ICU2 600 60
ICU1 - 600 20 3×D4
DSU2 D4 400 30 ICU1 - 600 20
3×D4 DSU1 D4 400 30
DSU1 D4 400 10 DSU2* D4 400 40
ICU1 - 1000 20 DSU3 D4 400 50
DSU2* D4 400 30 ICU2 - 600 60
DSU3 D4 400 40
3AFE68700281 Rev 0.5
* Cubicle with the control electronics.

Abbreviations and option codes – The table below describes the abbreviations of the cubicle names and module
names. The table also shows the option codes which indicate the use of certain optional cubicle.
Abbr. Description Option code

DSU Diode supply module cubicle -
D3 Diode supply module, frame size D3 -
D4 Diode supply module, frame size D4 -
ICU Incoming cubicle. Included with main breaker or contactor option. +F250 or +F255
RFI1 RFI filter cubicle. Included with RFI filter option. +E202
Index – Each cubicle has a predesigned position in the supply unit line-up which is indicated by an index. The lower
the index, the further left the cubicle is positioned in the unit.

163
Cubicle widths and positions in inverter units

The table below shows the inverter unit cubicle widths in millimetres and the position
(index) in the inverter unit line-up. See Cubicle widths and positions in cabinet line-
ups on page 162 for the inverter modules and inverter units used in each ACS800-
07LC.
Cubicle Inverter Width Index Cubicle Inverter Width Index
modules modules
Cubicle Inverter Width Index
modules SFU1 - 1000 31 OPU1 - 400 40
1×R8i 400 V 0390-3, 0470-3, 0620-3 SFU2 - 1000 32 OPU2 - 400 50
INU1* 1×R8i 3001) 10 3×R8i 400 V 1790-3 INU4 3×R8i 700 60
OPU1 - 300 30 INU3* 3×R8i 700 10 6×R8i all 690 V units
OCU1 - 300 30 OPU1 - 400 30 INU3* 3×R8i 700 10
SFU1 - 1000 31 OCU1 - 500 30 OPU3 - 600 30
1×R8i 500 V 0470-5, 0550-5, 0730-5 SFU1 - 1000 31 SFU1 - 1000 31
INU1* 1×R8i 300 1)
10 SFU2 - 1000 32 SFU2 - 1000 32
OPU1 - 300 30 SFU3 - 1000 33 SFU3 - 1000 33
OCU1 - 300 30 3×R8i 500 V -2120-5 INU4 3×R8i 700 60
SFU1 - 1000 31 INU3* 3×R8i 700 10 7×R8i 690 V only
1×R8i 690 V 0550-7, 0700-7 OPU1 - 400 30 INU3* 3×R8i 700 10
INU1* 1×R8i 3001) 10 OCU1 - 500 30 SFU1 - 1000 31
OPU1 - 300 30 SFU1 - 1000 31 SFU2 - 1000 32
OCU1 - 300 30 SFU2 - 1000 32 SFU3 - 1000 33
SFU1 - 1000 31 SFU3 - 1000 33 SFU4 - 1000 34
2×R8i 400 V 0760-3 4×R8i all 400 V OPU1 - 400 40
INU1* 2×R8i 500 10 INU1* 2×R8i 500 10 OPU2 - 400 50
OPU1 - 300 30 OPU3 - 600 30 INU1 2×R8i 500 60
OCU1 - 500 30 SFU1 - 1000 31 INU2 2×R8i 500 70
SFU1 - 1000 31 SFU2 - 1000 32 8×R8i 690 V only
2×R8i 500 V 0930-5 SFU3 - 1000 33 INU3* 3×R8i 700 10
INU1* 2×R8i 500 10 SFU4 - 1000 34 INU2 2×R8i 500 20
OPU1 - 300 30 INU2 2×R8i 500 70 SFU1 - 1000 31
OCU1 - 500 30 4×R8i 500 V units SFU2 - 1000 32
SFU1 - 1000 31 INU1* 2×R8i 500 10 SFU3 - 1000 33
2×R8i all 690 V units 0940-7, 1070-7, 1370-7 OPU3 - 600 30 SFU4 - 1000 34
INU1* 2×R8i 500 10 SFU1 - 1000 31 OPU1 - 400 40
OPU1 - 300 30 SFU2 - 1000 32 OPU2 - 400 50
OCU1 - 500 30 SFU3 - 1000 33 INU4 3×R8i 700 60
SFU1 - 1000 31 INU2 2×R8i 500 70 9×R8i 690 V only
2×R8i 400 V 0920-3, 1210-3 4×R8i all 690 V units INU3* 3×R8i 700 10
INU1* 2×R8i 500 10 INU1* 2×R8i 500 10 INU4 3×R8i 700 20
OPU1 - 300 30 OPU1 - 400 30 SFU1 - 1000 31
OCU1 - 500 30 SFU1 - 1000 31 SFU2 - 1000 32
SFU1 - 1000 31 SFU2 - 1000 32 SFU3 - 1000 33
SFU2 - 1000 32 INU2 2×R8i 500 70 SFU4 - 1000 34
2×R8i 500 V1070-5, 1430-5 5×R8i all 400 V and 500V units SFU5 - 1000 35
INU1* 2×R8i 500 10 INU3* 3×R8i 700 10 OPU1 - 400 40
OPU1 - 300 30 SFU1 - 1000 31 OPU2 - 400 50
OCU1 - 500 30 SFU2 - 1000 32 INU5 3×R8i 700 60
SFU1 - 1000 31 SFU3 - 1000 33 10×R8i 690 V only
SFU2 - 1000 32 SFU4 - 1000 34 INU3* 3×R8i 700 10
3×R8i 400 V 1370-3 OPU1 - 400 40 INU1 2×R8i 500 20
INU3* 3×R8i 700 10 OPU2 - 400 50 SFU1 - 1000 31
OPU1 - 400 30 INU1 2×R8i 500 70 SFU2 - 1000 32
OCU1 - 500 30 5×R8i all 690 V units SFU3 - 1000 33
SFU1 - 1000 31 INU3* 3×R8i 700 10 SFU4 - 1000 34
SFU2 - 1000 32 OPU3 - 600 30 SFU5 - 1000 35
3×R8i 500 V 1590-5 SFU1 - 1000 31 OPU3 - 600 40
INU3* 3×R8i 700 10 SFU2 - 1000 32 OPU2 - 400 50
OPU1 - 400 30 SFU3 - 1000 33 INU4 3×R8i 700 60
OCU1 - 500 30 INU1 2×R8i 500 70 INU2 2×R8i 500 70
SFU1 - 1000 31 6×R8i all 400 V and 500V units 3AFE68700281 Rev 0.5
SFU2 - 1000 32 INU3* 3×R8i 700 10
* Cubicle with the control electronics.
3×R8i all 690 V units 1590-7, 2030-7 SFU1 - 1000 31
1) Width increases by 100 mm if unit is
INU3* 3×R8i 700 10 SFU2 - 1000 32
OPU1 - 300 30 SFU3 - 1000 33 equipped with DC switch option (+F266)
OCU1 - 500 30 SFU4 - 1000 34
SFU5 - 1000 35

164
Abbreviations and option codes – The table below describes the abbreviations of the cubicle and module names.
The table also shows the option codes which indicate the use of certain optional cubicle.
Abbr. Description Option code

INU Inverter module cubicle -
OCU Output contactor cubicle +F269
OPU Common motor terminals cubicle +H359
R8i Inverter module, frame size R8i -
SFU Sine output filter cubicle +E206
Index – Each cubicle has a predesigned position in the inverter unit line-up which is indicated by an index. The lower
the index, the further left the cubicle is positioned in the unit.
Cubicle widths and positions in brake units

The table below shows the brake unit cubicle widths in millimetres and the position
(index) in the brake unit line-up. Note: Resistors are located in a separate cabinet
line-up.
Brake chopper cubicles Brake resistor cubicles
Cubicle Chopper Module Width Index Cubicle Resistor Module Width Index
1×NBRW669, 690V only Resistor cubicles with 1×NBRW669, 690V only
BRC1 1×NBRW 400 10 BRR1 2×SAFUR 800
3AFE68700281 Rev 0.5
Abbreviations – The table below describes the abbreviations of the cubicle and module names.
Abbr. Description
NBRW Brake chopper module / cubicle
SAFUR Brake resistor module / cubicle

165
Option codes – The table below shows which chopper and resistor cubicles are in use depending on the option
codes selected.
Option Brake power Chopper Resistor

+D150+1D150 400 kW NBRW669 -
+D150+2D150 800 kW 2 × NBRW669 -
+D150+3D150 1200 kW 3 × NBRW669 -
+D150+4D150 1600 kW 4 × NBRW669 -
+D150+5D150 2000 kW 5 × NBRW669 -
+D150+6D150 2400 kW 6 × NBRW669 -
+D151+1D150 400 kW NBRW669 2 × SAFUR200F500
+D151+2D150 800 kW 2 × NBRW669 2 × (2 × SAFUR200F500)
+D151+3D150 1200 kW 3 × NBRW669 3 × (2 × SAFUR200F500)
+D151+4D150 1600 kW 4 × NBRW669 4 × (2 × SAFUR200F500)
+D151+5D150 2000 kW 5 × NBRW669 5 × (2 × SAFUR200F500)
+D151+6D150 2400 kW 6 × NBRW669 6 × (2 × SAFUR200F500)
Index – Each cubicle has a predesigned position in the brake unit line-up which is indicated by an index (shown in
data tables later in this chapter). The lower the index, the further left the cubicle is positioned in the unit.
Cubicle widths and positions in cooling units

The table below shows the cooling unit widths in millimetres.
Cubicle No. of pumps Width
Unit type ACS800-1007LC-0070
LCU1 1 300
Unit type ACS800-1007LC-0195
LCU1 2 600
Abbreviations – The table below describes the abbreviations of the cubicle names.
Abbr. Description
LCU Cooling unit cubicle
Option codes – The table below shows the cooling unit position (either at the end of the drive cabinet line-up, or
stand-alone) and size depending on the option codes selected.
Option code Description
+C138 Line-up connected cooling unit
+C139 Stand-alone cooling unit
+C140 Single-pump cooling unit (ACS800-1007LC-0070)
+C141 Two-pump cooling unit (ACS800-1007LC-0195)

166

3AFE68620902 Rev B / EN
EFFECTIVE: 24.10..2006
ABB Oy ABB Inc. ABB Beijing Drive Systems Co. Ltd.

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

Hardware Manual ACS800-07LC Drives

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ACS800

DRIVE HARDWARE MANUAL1) Code (EN)

ACS800-07LC Hardware Manual 3AFE68620902

SUPPLY UNIT FIRMWARE MANUAL1)

INVERTER UNIT FIRMWARE MANUALS, SUPPLEMENTS AND

LIQUID COOLING UNIT MANUAL 3)

ACS800-1007LC Liquid-cooling Unit User's Manual 3AFE68621101

© 2006 ABB Oy. All Rights Reserved.

What this chapter contains

Usage of warnings and notes

Danger; electricity warning warns of high voltage which can cause

General danger warning warns about conditions, other than those

Installation and maintenance work

Use of the hand-operated winch

Work on the liquid cooling system

• Drain the unit before storing in temperatures below 0°C.

Printed circuit boards and fibre optic cables

WARNING! The printed circuit boards contain components sensitive to electrostatic

Permanent magnet motor drives

Installation and maintenance work

Start-up and operation

ACS800 liquid-cooled single drive manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

About this manual

Inverter unit control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Planning the electrical installation

Emergency stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Replacing the fan of the diode supply module cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

The internal cooling circuit

Motor control and I/O board (RMIO) specification

Dimensions and weights

About this manual

What this chapter contains

Common chapters for several products

Categorization according to the frame size

About this manual

About this manual

Installation and commissioning flowchart

Unpack and check the units. Delivery check, page 44

Only intact units may be started up!

Check the installation site. Mechanical installation, page 41

Route the cables. Routing the cables, page 73

Mount the cabinet line-up. Mechanical installation, page 41

Check the installation. Installation checklist, page 103

About this manual

Terms and abbreviations

About this manual

What this chapter contains

Overview – 6 or 12-pulse drive with modules 1×D4+2×R8i, no built-in main

Inverter module cubicle (2×R8i) contains:

Doors closed Doors open

Overview – 6-pulse drive with modules 2×D4+4×R8i and a built-in main

Inverter module cubicles (2×2×R8i) contain:

Doors open, shrouds removed

Swing-out frame in the supply module cubicle

1. Supply control unit [RDCU] including the

2. RDCO DDCS Adapter

3. DSCB board [DSCB]

7 8 4. Supply unit measuring adapter [NAIO-03F]

5. 24 VDC power supply

6. 24 VDC back-up accumulator

7. Circuit breakers (auxiliary circuits)

10. Safety relay and time relays of supply unit

Swing-out frame in the inverter module cubicle