ACS800 04 Technical Manual 0 55kW To 160kW

ACS800
Hardware Manual
ACS800-04 Drive Modules (0.55 to 160 kW)
ACS800-U4 Drive Modules (0.75 to 200 HP)
ACS800 Single Drive Manuals
HARDWARE MANUALS (appropriate manual is included in the

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

3AFE64382101 (English)
ACS800-01/U1/04 Marine Supplement 0.55 to 160 kW (0.75 to
200 HP) 3AFE64291275 (English)
CS800-11/U11 Hardware Manual 5.5 to 110 kW (7.5 to 125 HP)
ACS800-31/U31 Hardware Manual 5.5 to110 kW (7.5 to 125 HP)
ACS800-02/U2 Hardware Manual 90 to 500 kW (125 to 600 HP)
ACS800-04/U4 Hardware Manual 0.55 to 160 kW (0.75 to 200 HP)
ACS800-04/04M/U4 Hardware Manual 45 to 560 kW (60 to
ACS800-04/04M/U4 Cabinet Installation 45 to 560 kW (60 to
ACS800-07/U7 Hardware Manual 45 to 560 kW (50 to 600 HP)
ACS800-07/U7 Dimensional Drawings 45 to 560 kW (50 to
600 HP) 3AFE64775421
ACS800-07 Hardware Manual 500 to 2800 kW
ACS800-17 Hardware Manual 55 to 2500 kW (75 to 2800 HP)
ACS800-37 Hardware Manual 55 to 2700 kW (75 to 3000 HP)
• Safety instructions
• Electrical installation planning
• Mechanical and electrical installation
• Motor control and I/O board (RMIO)
• Maintenance
• Technical data
• Dimensional drawings
• Resistor braking
FIRMWARE MANUALS, SUPPLEMENTS AND GUIDES

(appropriate documents are included in the delivery)
Standard Application Program Firmware Manual

System Application Program Firmware Manual
Application Program Template Firmware Manual
Master/Follower 3AFE64590430 (English)
Pump Control Application Program Firmware Manual
Extruder Control Program Supplement 3AFE64648543 (English)
Centrifuge Control Program Supplement 3AFE64667246 (English)
Traverse Control Program Supplement 3AFE64618334 (English)
Crane Control Program Firmware Manual 3BSE11179 (English)
Adaptive Programming Application Guide
OPTION MANUALS (delivered with optional equipment)
Fieldbus Adapters, I/O Extension Modules etc.

ACS800-04 Drive Modules
0.55 to 160 kW
ACS800-U4 Drive Modules
0.75 to 200 HP
Hardware Manual
3AFE68372984 Rev C EN
EFFECTIVE: 16.2.2007
© 2007 ABB Oy. All Rights Reserved.

5
Safety instructions
What this chapter contains

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

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

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

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

These warnings are intended for all who work on the drive, motor cable or motor.
WARNING! Ignoring the following instructions can cause physical injury or death, or
damage to the equipment:
• Only qualified electricians are allowed to install and maintain the drive.
• Never work on the drive, the motor cable or the motor when main power is
applied. After switching off the input power, always wait for 5 min to let the
intermediate circuit capacitors discharge before you start working on the drive,
the motor or the motor cable.
Always ensure by measuring with a multimeter (impedance at least 1 Mohm)
that:
1. voltage between drive input phases U1, V1 and W1 and the frame is close to
0V
2. voltage between terminals UDC+ and UDC- and the frame is close to 0 V.
• Do not work on the control cables when power is applied to the drive or to the
external control circuits. Externally supplied control circuits may cause
dangerous voltages inside the drive even when the main power on the drive is
switched off.
• Do not make any insulation or voltage withstand tests on the drive or drive
modules.
• When reconnecting the motor cable, always check that the phase order is
correct.
Note:
• The motor cable terminals on the drive are at a dangerously high voltage when
the input power is on, regardless of whether the motor is running or not.
• The brake control terminals (UDC+, UDC-, R+ and R- terminals) carry a

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

may be present on the terminals of relay outputs RO1 to RO3 or on the optional
AGPS board (Prevention of Unexpected Start).
• The Prevention of Unexpected Start function does not remove the voltage from
the main and auxiliary circuits.
• At installation sites above 2000 m (6562 ft), the terminals of the RMIO board
and optional modules attached to the board do not fulfil the Protective Extra
Low Voltage (PELV) requirements stated in EN 50178.
Safety instructions
7
Grounding
These instructions are intended for all who are responsible for the grounding of the
drive.
WARNING! Ignoring the following instructions can cause physical injury, death,
increased electromagnetic interference and equipment malfunction:
• Ground the drive, motor and adjoining equipment to ensure personnel safety in
all circumstances, and to reduce electromagnetic emission and interference.
• 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).
• In first environment (EU EMC Directive): make a 360° high frequency

grounding of the motor cable entry at the cabinet lead-through.
• Do not install a drive with EMC filter option +E202 or +E200 on an ungrounded
power system or a high resistance-grounded (over 30 ohms) power system.
Note:
• Power cable shields are suitable for equipment grounding conductors only
when adequately sized to meet safety regulations.
• As the normal leakage current of the drive is higher than 3.5 mA AC or 10 mA

DC (stated by EN 50178, 5.2.11.1), a fixed protective earth connection is
required.
Safety instructions
8
Mechanical installation and maintenance

These instructions are intended for all who install and service the drive.
WARNING! Ignoring the following instructions can cause physical injury or death,
or damage to the equipment:
• Handle the unit carefully.
• The drive is heavy. Do not lift it alone. Place the unit only on its back.
• Beware of hot surfaces. Some parts, such as heatsinks of power

semiconductors, remain hot for a while after disconnection of the electrical
supply.
• Make sure that dust from borings and grindings does not enter the drive when
installing. Electrically conductive dust inside the unit may cause damage or
malfunctioning.
• Ensure sufficient cooling.
• Do not fasten the drive by riveting or welding.
Printed circuit boards
WARNING! Ignoring the following instructions can cause damage to the printed
circuit boards:
• The printed circuit boards contain components sensitive to electrostatic

discharge. Wear a grounding wrist band when handling the boards. Do not
touch the boards unnecessarily.
Fibre optic cables
WARNING! Ignoring the following instructions can cause equipment malfunction

and damage to the fibre optic cables:
• Handle the fibre optic cables with care. When unplugging optic cables, always
grab the connector, not the cable itself. Do not touch the ends of the fibres with
bare hands as the fibre is extremely sensitive to dirt. The minimum allowed
bend radius is 35 mm (1.4 in.).
Safety instructions
9
Operation
These warnings are intended for all who plan the operation of the drive or operate
the drive.
WARNING! Ignoring the following instructions can cause physical injury or death,
or damage to the equipment:
• Before adjusting the drive and putting it into service, make sure that the motor
and all driven equipment are suitable for operation throughout the speed range
provided by the drive. The drive can be adjusted to operate the motor at
speeds above and below the speed provided by connecting the motor directly
to the power line.
• Do not activate automatic fault reset functions of the Application Program if

dangerous situations can occur. When activated, these functions will reset the
drive and resume operation after a fault.
• Do not control the motor with the disconnecting device (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 (with
Standard / Motion Control Application Program) will start immediately after fault
reset unless the drive is configured for 3-wire (a pulse) start/stop.
• When the control location is not set to Local (L not shown in the status row of
the display), the stop key on the control panel will not stop the drive. To stop
the drive using the control panel, press the LOC/REM key and then the stop
key .
Safety instructions
10
Permanent magnet motor

These are additional warnings concerning permanent magnet motor drives. Ignoring
the instructions can cause physical injury or death, or damage to the equipment.
Installation and maintenance work
WARNING! Do not work on the drive when the permanent magnet motor is rotating.
Also, when the supply power is switched off and the inverter is stopped, a rotating
permanent magnet motor feeds power to the intermediate circuit of the drive and the
supply connections become live.
Before installation and maintenance work on the drive:
• Stop the motor.
• Ensure that the motor cannot rotate during work. Prevent the start-up of any
drives in the same mechanical group by opening the “prevention of unexpected
start” switch and padlocking it. Make sure that no other system, like hydraulic
crawling drives, are able to rotate the motor directly or through any mechanical
connection like felt, nip, rope, etc.
• 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 Single Drive Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety instructions
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Mechanical installation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fibre optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Permanent magnet motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Start-up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Table of contents
About this manual

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Categorization according to the frame size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Categorization according to the + code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation and commissioning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
ACS800-04/U4
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Main circuit and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Planning the cabinet assembly
Table of contents
12
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Cabinet construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Disposition of the devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Grounding of mounting structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Free space around the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Cooling and degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Preventing the recirculation of hot air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Outside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Cabinet layout example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Cabinet heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Mounting the optional control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Installing the control panel directly on the cabinet door . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Control panel mounting platform kit (RPMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
EMC requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Mechanical installation
Unpacking the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Requirements for the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Flange mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Planning the electrical installation

Motor selection and compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Permanent magnet synchronous motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Supply connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Disconnecting device (means) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
EEA / Europe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
US . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Main contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Thermal overload and short circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Thermal overload protection of the drive and the input and motor cables . . . . . . . . . . . . . . .48
Thermal overload protection of the motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Protection against short-circuit in the motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Protection against short circuit inside the drive or in the supply cable . . . . . . . . . . . . . . . . . .49
Ground fault protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Emergency stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Prevention of Unexpected Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Table of contents
13
Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Power factor compensation capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Equipment connected to the motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Installation of safety switches, contactors, connection boxes, etc. . . . . . . . . . . . . . . . . . . . . 54
Bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Before opening a contactor (DTC control mode selected) . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Protecting the relay output contacts and attenuating disturbances in case of inductive loads . . . . 55
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Connection of a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Installation sites above 2000 metres (6562 feet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Electrical installation
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Input cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Power cable connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Grounding the motor cable shield at the motor end . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Frame sizes R2 to R4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Frame size R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Frame size R6: Cable lug installation [16 to 70 mm2 (6 to 2/0 AWG) cables] . . . . . . . 64
Power cable protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Frame size R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Frame size R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Warning sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
360 degrees grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
When the outer surface of the shield is covered with non-conductive material . . . . . . 69
Connecting the shield wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Cabling of I/O and fieldbus modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Pulse encoder module cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Installation of optional modules and PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Fibre optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
External +24 V power supply for the RMIO board via terminal X34 . . . . . . . . . . . . . . . . . . . . . . . . 71
Parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Connecting +24 V external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Prevention of Unexpected Start, AGPS board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
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14
Motor control and I/O board (RMIO)

Note on terminal labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Note on external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
External control connections (non-US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
External control connections (US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
RMIO board specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Analogue inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Constant voltage output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Auxiliary power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Analogue outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
DDCS fibre optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
24 VDC power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Installation checklist
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Maintenance
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Fan replacement (R2, R3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Fan replacement (R4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Additional fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Replacement (R2, R3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Replacement (R4, R5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Replacement (R6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Technical data
IEC data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
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15
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Cooling characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Cooling requirements for flange mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Mains cable fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
gG fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Cable entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Dimensions, weights and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
NEMA data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Input cable fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Cable Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Input power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
AGPS-11C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Compliance with the EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Compliance with the EN 61800-3 (2004) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
First environment (drive of category C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Second environment (drive of category C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
“C-tick” marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Compliance with IEC 61800-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
First environment (drive of category C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Marine type approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
UL/CSA markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
UL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Equipment warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Product protection in the US . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Dimensional drawings
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Frame size R2 (with optional control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Table of contents
16
Frame size R5 (with optional control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

Frame size R6 (with optional control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Flange mounting kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Flange mounting kit for frame size R2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
AGPS board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Resistor braking
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Availability of brake choppers and resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
How to select the correct drive/chopper/resistor combination . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Optional brake chopper and resistor(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Resistor installation and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Protection of frame sizes R2 to R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Protection of frame size R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Brake circuit commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
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17
About this manual

This chapter describes the intended audience and contents of this manual. It
contains a flowchart of steps in checking the delivery, installing and commissioning
the drive. The flowchart refers to chapters/sections in this manual and other
manuals.
Compatibility
The manual is compatible with ACS800-04/U4 (frame sizes R2...R6).
Intended audience
This manual is intended for people who plan the installation, install, commission, use
and service the drive. Read the manual before working on the drive. The reader is
expected to know the fundamentals of electricity, wiring, electrical components and
electrical schematic symbols.
This manual is written for readers worldwide. Both SI and imperial units are shown.
Special US instructions for installations within the United States that must be
installed per the National Electrical Code and local codes are marked with (US).
Categorization according to the frame size

Some instructions, technical data and dimensional drawings which concern only
certain frame sizes are marked with the symbol of the frame size R2, R3... or R6.
The frame size is not marked on the drive designation label. To identify the frame
size of your drive, see the rating tables in chapter Technical data.
Categorization according to the + code

The instructions, technical data and dimensional drawings which concern only
certain optional selections are marked with + codes, e.g. +E202. The options
included in the drive can be identified from the + codes visible on the type
designation label of the drive. The + code selections are listed in chapter ACS800-
04/U4 in section Type code.
About this manual

18
Contents
The chapters of this manual are briefly described below.
Safety instructions give safety instructions for the installation, commissioning,
operation and maintenance of the drive.
About this manual lists the steps in checking the delivery and installing and
commissioning the drive and refers to chapters/sections in this manual and other
manuals for particular tasks.
ACS800-04/U4 describes the drive.
Planning the cabinet assembly guides in planning the installation of a drive module
into a user-defined cabinet.
Mechanical installation instructs how to place and mount the drive.
Planning the electrical installation instructs on the motor and cable selection, the
protections and the cable routing.
Electrical installation shows how to wire the drive.
Motor control and I/O board (RMIO) shows the external control connections to the
I/O board.
Installation checklist contains a list for checking the mechanical and electrical
installation of the drive.
Maintenance contains preventive maintenance instructions.
Technical data contains the technical specifications of the drive, e.g. the ratings,
sizes and technical requirements, provisions for fulfilling the requirements for CE
and other markings and warranty policy.
Dimensional drawings contains the dimensional drawings of the drive.
Resistor braking describes how to select, protect and wire brake choppers and
resistors. The chapter also contains the technical data.
About this manual

19
Installation and commissioning flowchart
Task See
Identify the frame size of your drive: R2, R3, R4, R5 Technical data: IEC data or NEMA data
or R6.
Plan the installation. Technical data

Check the ambient conditions, ratings, required Planning the electrical installation
cooling air flow, input power connection, compatibility
Option manual (if optional equipment is
of the motor, motor connection, and other technical
included)
data.
Select the cables.
Unpack and check the units. Mechanical installation: Unpacking the unit
Check that all necessary optional modules and If the converter has been non-operational for
equipment are present and correct. more than one year, the converter DC link
Only intact units may be started up. capacitors need to be reformed. Ask ABB for
instructions.
Check the installation site. Mechanical installation: Before installation

Technical data
If the drive is about to be connected to an IT ACS800-04/U4: Type code

(ungrounded) system, check that the drive is not
For instructions on how to disconnect the EMC
equipped with EMC filtering.
filtering, contact ABB.
Install the drive in a cabinet. Mechanical installation
Route the cables. Planning the electrical installation: Routing the

cables
Check the insulation of the motor and the motor Electrical installation: Checking the insulation of
cable. the assembly
About this manual

20
Task See
Connect the power cables. Electrical installation, Motor control and I/O
Connect the control and the auxiliary control cables. board (RMIO), Resistor braking (optional) and
the optional module manual delivered with the
module.
Check the installation. Installation checklist
Commission the drive. Appropriate Firmware Manual
Commission the optional brake chopper (if present). Resistor braking
Operating of the drive: start, stop, speed control etc. Appropriate Firmware Manual
Product and service inquiries

Address any inquiries about the product to your local ABB representative, quoting
the type code and serial number of the unit in question. A listing of ABB sales,
support and service contacts can be found by navigating to www.abb.com/drives and
selecting Drives – World wide service contacts on the right pane.
Product training
For information on ABB product training, navigate to www.abb.com/drives and select
Drives – Training courses on the right pane.
Providing feedback on ABB Drives manuals

Your comments on our manuals are welcome. Go to www.abb.com/drives, then
select successively Drives – Document Library – Manuals feedback form on the right
pane.
About this manual

21
Terms and abbreviations

Term/Abbreviation Explanation
CDP312R Drive control panel
DDCS Distributed Drives Communication System; a protocol used in optical fibre

communication inside and between ABB drives.
EMC Electromagnetic Compatibility
Frame (size) Size of the frame into which the drive module is assembled. Several
supply modules with different nominal powers may have the same frame
size. The term refers to modules that have a similar mechanical
construction.
To determine the frame size of a drive module, refer to the rating tables in
chapter Technical data.
IGBT Insulated Gate Bipolar Transistor; a voltage-controlled semiconductor type

widely used in inverters due to their easy controllability and high switching
frequency.
I/O Input/Output
AGPS Gate driver Power Supply board. An optional board used to implement the
Prevention of Unexpected Start function.
RDCO DDCS communication option module
RDIO Digital I/O Extension Module
RFI Radio-frequency interference
RINT Main circuit board
RMIO Motor control and I/O board. The external I/O control signals are
connected to RMIO.
RPMP Control panel mounting platform kit
About this manual

22
About this manual

23
ACS800-04/U4

This chapter describes the operating principle and construction of the drive in short.
Layout
The ACS800-04/U4 (frame sizes R2 to R6) is an IP20 drive module for controlling
AC motors. It is to be installed into a cabinet by the customer with wall fastening.
Control panel CDP312R Frame size R2

(optional)
Option slots
Power cable
terminal
Heatsink
PE
Location of the components vary depending on the frame size.
ACS800-04/U4
24
Type code
The type code contains information on the specifications and configuration of the
drive. The first digits from left express the basic configuration (e.g. ACS800-04-
0016-3). The optional selections are given thereafter, separated by + signs (e.g.
+E202). The main selections are described below. Not all selections are available for
all types. For more information, refer to ACS800 Ordering Information
[3AFE64556568 (English)], available on request.
Selection Alternatives
Product series ACS800 product series
Type 04 Drive module. When no options are selected: IP20, no control panel, no
EMC filter, Standard Application Program, brake chopper in frame sizes
R2, R3, and R4 (only 690 V), boards without coating, one set of manuals.
U4 Drive module (USA). When no options are selected: UL open type, no
control panel, no EMC filter, Standard Application Program, brake
chopper in frame sizes R2, R3, and R4 (only 690 V), boards without
coating, one set of manuals.
Size See Technical data: IEC data or NEMA data.
Voltage range 2 208/220/230/240 VAC
(nominal rating in bold) 3 380/400/415 VAC
5 380/400/415/440/460/480/500 VAC
7 525/575/600/690 VAC
+ options
Control panel J400 Control panel CDP312R assembled on the drive module
J414 Control panel holder for frame sizes R2, R3 and R4 (not to be used with
option J400)
Construction C132 Marine drive (coated boards included)
C135 Flange mounting. Flange mounting plate assembled. IP55 for heat sink
side and IP20 for drive front side.
Filter E200 EMC/RFI filter for second environment TN (grounded) system, drive
category C3
E202 EMC/RFI filter for first environment TN (grounded) system, drive category
C2. (Not available for 690 V units.)
E210 EMC/RFI filter for second environment TN/IT (grounded/ungrounded)
system, drive category C3 (frame size R6 only)
Resistor braking D150 Brake chopper. Included as standard in frame sizes R2, R3 and R4 (only
690 V).
Safety Q950 Prevention of Unexpected Start: AGPS board and 3 m connection wire.
Fieldbus K... Refer to ACS800 Ordering Information [3AFE64556568 (English)].
I/O L...
Application program N...
Manual language R...
Specialities P901 Coated boards
P904 Extended warranty
ACS800-04/U4
25
Main circuit and control
Diagram
This diagram shows the control interfaces and the main circuit of the drive. Location
of terminals vary depending on the drive frame size.
Drive
Optional module 1: RMBA, RAIO, RDIO,

Motor Slot1 RDNA, RLON, RIBA, RPBA, RCAN, RCNA,
control and RMBP, RETA, RRIA or RTAC
I/O board
(RMIO)
Slot2
Optional module 2: RTAC, RAIO, RRIA or
RDIO
External control via
analogue/digital X33 DDCS communication option module 3:
inputs and outputs RDCO-01, RDCO-02 or RDCO-03
The fibre optic channels provided by the
X41
RDCO module can be used for fieldbus
connection (Nxxx fieldbus adapter modules),
Prevention of Unexpected
PC connection (DriveWare® PC tools) or
Start (AGPS board)
Advant Fieldbus 100 connection (e.g.
AC 800M, AC80)
= ~
Input power
~ = Output power
Brake chopper in frame sizes R2, R3 and

690 V frame R4 (optional in other frame
sizes).
R- UDC+ UDC-
R+
ACS800-04/U4
26
Operation
This table describes the operation of the main circuit in short.
Component Description
Six-pulse rectifier Converts the three-phase AC voltage to DC voltage.
Capacitor bank Energy storage which stabilizes the intermediate circuit DC voltage.
IGBT inverter Converts the DC voltage to AC voltage and vice versa. The motor
operation is controlled by switching the IGBTs.
Printed circuit boards

The drive contains the following printed circuit boards as standard:
• main circuit board (RINT)
• motor control and I/O board (RMIO)
• EMC filter board (RRFC) when EMC equipment is selected or varistor board
(RVAR) otherwise.
Motor control
The motor control is based on the Direct Torque Control (DTC) method. Two phase
currents and DC link voltage are measured and used for the control. The third phase
current is measured for earth fault protection.
ACS800-04/U4
27

This chapter guides in planning the installation of a drive module into a user-defined
cabinet. The issues discussed are essential for safe and trouble-free use of the drive
system.
Note: The installation examples in this manual are provided only to help the installer
in designing the installation. The installation must always be designed and made
according to applicable local laws and regulations. ABB does not assume any
liability whatsoever for any installation which breaches the local laws and/or other
regulations.
Cabinet construction
The cabinet frame must be sturdy enough to carry the weight of the drive
components, control circuitry and other equipment installed in it.
The cabinet must protect the drive module against contact and meet the
requirements for dust and humidity (see chapter Technical data).
Disposition of the devices

For easy installation and maintenance, a spacious layout is recommended. Sufficient
cooling air flow, obligatory clearances, cables and cable support structures all
require space.
For layout examples, see section Cabinet layout example.
Grounding of mounting structures

Make sure all cross-members or shelves on which components are mounted are
properly grounded and the connecting surfaces left unpainted.
Note: Ensure that the modules are properly grounded through their fastening points
to the installation base.

28
Free space around the unit

The modules can be installed side by side. Recommended free space above and
below the drive to enable cooling air flow, service and maintenance is shown below
in millimetres and [inches].
The temperature of the cooling air entering the unit must not exceed the maximum
allowed ambient temperature. See section Ambient conditions in chapter Technical
data.
200 [7.9]
300 [12]
IP20 (UL open type)

29
Cooling and degrees of protection

The cabinet must have enough free space for the components to ensure sufficient
cooling. Observe the minimum clearances given for each component.
The air inlets and outlets must be equipped with gratings that
• guide the air flow
• protect against contact
• prevent water splashes from entering the cabinet.
The drawing below shows two typical cabinet cooling solutions. The air inlet is at the
bottom of the cabinet, while the outlet is at the top, either on the upper part of the
door or on the roof.
Air outlet
Air inlet
Arrange the cooling air flow through the modules so that the requirements given in
chapter Technical data are met:
• cooling air flow
Note: The values in Technical data apply to continuous nominal load. If the load is cyclic or less
than nominal, less cooling air is required.
• allowed ambient temperature

• the air inlet and outlet sizes required for the module cooling and recommended
filter material (if used).
In addition to the above, the heat dissipated by cables and other additional
equipment must also be ventilated.
The internal cooling fans of the modules are usually sufficient to keep the component
temperatures low enough in IP22 (UL type 1) cabinets.

30
In IP54 (UL type 12) cabinets, thick filter mats are used to prevent water splashes
from entering the cabinet. This entails the installation of additional cooling
equipment, such as a hot air exhaust fan.
The installation site must be sufficiently ventilated.
Preventing the recirculation of hot air
Normal vertical mounting Flange mounting
Main
Cabinet (side view) air Cabinet (side view)
flow
out
HOT
AREA Air flow out
Main air flow out HOT AREA
Air baffle
Air baffle plate
plates
COOL AREA COOL AREA
Main air flow in Air flow in
Main
air
flow
in
Outside the cabinet

Prevent hot air circulation outside the cabinet by leading the outcoming hot air away
from the area where the inlet air to the cabinet is taken. Possible solutions are listed
below:
• gratings that guide air flow at the air inlet and outlet
• air inlet and outlet at different sides of the cabinet
• cool air inlet in the lower part of the front door and an extra exhaust fan on the
roof of the cabinet.

31
Inside the cabinet

Prevent hot air circulation inside the cabinet with leak-proof air baffle plates. No
gaskets are usually required.
When several modules are installed vertically in one cabinet, the hot air from one
module must not be allowed to enter another module. In a cabinet with multiple
modules, a practical way of achieving this is to install a mounting plate to separate
the cool area (at the front part of the cabinet) from the hot area (back part). The
mounting plate can be fastened to two vertical pillars on both left and right. Since the
air outlet at the top of the modules points directly upwards, the air must be guided to
the hot area. See cabinet layout examples below.
Cabinet layout example
Vertical mounting
AC switch fuse
AC fuse bases
AC fuses
Airflow guides
du/dt filter Hot area
Cool area
Mounting
plates
Modules
Motor cable entries
Front view of three R2 Side view of three R3

modules in cabinet modules in cabinet

32
Cabinet heaters
Use a cabinet heater if there is a risk of condensation in the cabinet. Although the
primary function of the heater is to keep the air dry, it may also be required for
heating at low temperatures. When placing the heater, follow the instructions
provided by its manufacturer.
Mounting the optional control panel

The optional control panel CDP312R is factory assembled on the drive module.The
panel can also be fastened directly to the cabinet door or to a mounting platform.
Installing the control panel directly on the cabinet door

Fasten the control panel from the back side with two screws of one of the following
types:
• standard screw with nominal diameter of 4 mm (0.16 in.)
• tapping screw with nominal diameter of 4.2 mm (0.17 in.) DIN 7981 C, DIN 7982
C, DIN 7983 C or DIN 7976 C
• PT screw for thermoplastics with nominal diameter of 4 mm (0.16 in.).
View from outside the cabinet door
Control panel
Cabinet door
4...8 mm
(0.16...0.31 in.)
Control panel footprint
Tightening torque:
1 Nm (0.74 lbf ft) 10 mm (0.39 in.)

33
Control panel mounting platform kit (RPMP)

For installation of the mounting platform, see Control Panel Mounting Platform Kit
(RPMP) Installation Guide [3AFE64677560 (English)].
EMC requirements
Generally, the fewer and smaller the holes in the cabinet, the better the interference
attenuation. The maximum recommended diameter of a hole in galvanic metal
contact in the covering cabinet structure is 100 mm. Special attention must be paid
to the cooling air inlet and outlet gratings.
The best galvanic connection between the steel panels is achieved by welding them
together as no holes are necessary. If welding is not possible, the seams between
the panels are recommended to be left unpainted and equipped with special
conductive EMC strips to provide adequate galvanic connection. Usually, reliable
strips are made of flexible silicon mass covered with a metal mesh. The non-
tightened touch-contact of the metal surfaces is not sufficient, so a conductive
gasket between the surfaces is required. The maximum recommended distance
between assembly screws is 100 mm.
Sufficient high-frequency grounding network must be constructed in the cabinet to
avoid voltage differences and forming of high-impedance radiator structures. A good
high-frequency grounding is made with short flat copper braids for low inductance.
One-point high-frequency grounding cannot be used due to the long distances inside
the cabinet.
First environment EMC compliance *) of the drive requires 360° high frequency
grounding of the motor cable shields at their entries. The grounding can be
implemented by a knitted wire mesh screening as shown below.
Bare cable shield

Cable ties
Knitted wire mesh
Lead-through plate
Cable
Cabinet bottom plate
*) First environment EMC compliance is defined in section CE marking in chapter Technical data.

34
360° high frequency grounding of the control cable shields is recommended at their
entries. The shields can be grounded by means of conductive shielding cushions
pressed against the cable shield from both directions:
Bare cable shield Shielding cushion

(conductive)
Cabinet bottom plate
Cable
Cable grommet

35
Unpacking the unit

The drive is delivered in a box that also contains:
• plastic bag containing: screws (M3), clamps and cable lugs (2 mm2, M3) for
grounding the control cable screens
• residual voltage warning stickers
• hardware, firmware and other module manuals
• delivery documents.
Unpack the unit of frame sizes R2 to R5 as follows.
Tear
36
Delivery check
Check that there are no signs of damage. Before attempting installation and
operation, check the information on the type designation label of the drive to verify
that the unit is of the correct type. The label includes IEC rating, C-UL US, CSA,
C-tick and CE markings, a type code and a serial number, which allow individual
recognition of each unit. The first digit of the serial number refers to the
manufacturing plant. The next four digits refer to the unit’s manufacturing year and
week, respectively. The remaining digits complete the serial number so that there
are no two units with the same serial number.
The type designation label is attached to the heat sink and the serial number label to
the upper part of the back plate of the unit.
Type designation label
Serial number label
Before installation
Check the installation site according to the requirements below. See Dimensional
drawings for frame details.
Requirements for the installation site

See Technical data for the allowed operation conditions of the drive.
Floor
The floor/material below the cabinet should be non-flammable.
37
Installation procedure
1. Mark the locations for the four holes. The mounting points are shown in
Dimensional drawings. With frame sizes R2...R5, use the mounting template cut
from the package.
2. Fix the screws or bolts to the marked locations.
3. Position the drive onto the screws on the cabinet wall. Note: Lift the drive by its
chassis (R6: by its lifting holes).
4. Tighten the screws in the cabinet wall securely.
38
Flange mounting
The flange mounting plate is factory assembled on the drive. With flange mounting,
the degree of protection is IP55 for the heat sink side and IP20 for the drive front
side. The drive front side must always be housed in a cabinet.
R6 with flange mounting plate
Connect a drive with flange mounting plate as follows:

1. Make the appropriate mounting and screw holes for the drive into the mounting
plate. The sizes and locations of the holes vary according to the frame size. See
chapter Dimensional drawings. Screw holes can be replaced with rivet nuts.
Recommended type is closed M6 rivet nut, L = 23 mm, code 23351060030 /
Rivkle provided by Böllhoff (www.boellhoff.de).
2. Lift the drive by its lifting lugs and place it into the mounting hole.
3. Fix the washers and screws (M6) delivered with the drive (MRP code 68390419).
The tightening torque is 2 Nm.
Note: The flange mounting kit does not ground the drive. The drive needs to be
grounded according to instructions given in chapter Electrical installation.
Note: Maximum allowed vibration for the drive has not been tested with flange
mounting. If the drive is exposed to vibration, it is recommended to fix the drive also
from the normal mounting holes located on the heat sink. See section Installation
procedure.
39
R6 flange mounting
1
2 Lifting lug
Mounting plate
3
Washer
Screw
40
41

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

1. Select the motor according to the rating tables in chapter Technical data. Use the
DriveSize PC tool if the default load cycles are not applicable.
2. Check that the motor ratings lie within the allowed ranges of the drive control
program:
• motor nominal voltage is 1/2 ... 2 · UN of the drive
• motor nominal current is 1/6 ... 2 · I2hd of the drive in DTC control and
0 ... 2 · I2hd in scalar control. The control mode is selected by a drive parameter.
3. Check that the motor voltage rating meets the application requirements:
• If no resistor braking is in use, the motor voltage rating is UN.
UN = rated input voltage of the drive
• If frequent or long term brake cycles will be used, the motor voltage rating is
UACeq.
UACeq = UDC/1.35
where
UACeq is the equivalent AC power source voltage of the drive in V AC.
UDC is the maximum DC link voltage of the drive in V DC.
For resistor braking: UDC = 1.2 × 1.35 × UN.
See note 6 below the Requirements table.
4. Consult the motor manufacturer before using a motor in a drive system where the
motor nominal voltage differs from the AC power source voltage.
5. Ensure that the motor insulation system withstands the maximum peak voltage in
the motor terminals. See the Requirements table below for the required motor
insulation system and drive filtering.

42
Example: When the supply voltage is 440 V and the drive is operating in motor
mode only, the maximum peak voltage in the motor terminals can be
approximated as follows: 440 V · 1.35 · 2 = 1190 V. Check that the motor
insulation system withstands this voltage.
Protecting the motor insulation and bearings

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

43
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 and voids
the warranty.
Motor type Nominal mains Requirement for

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

and 350 kW or or
frame size < IEC frame size > IEC frame size > IEC
315 315 400
PN < 134 HP 134 HP < PN < PN > 469 HP
and frame size < 469 HP or frame size >
NEMA 500 or frame size > NEMA 580
NEMA 500
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: + N
HX_ and + CMF
AM_ PN > 500 kW: + N
+ CMF + du/dt
Old* form- 380 V < UN < 690 V Check with the + du/dt with voltages over 500 V + N + CMF
wound HX_ motor
and modular manufacturer.
Random- 0 V < UN < 500 V Enamelled wire + N + CMF
wound HX_ 500 V < UN < 690 V with fibre glass + du/dt + N + CMF
and AM_ ** taping

44

Manufacturer

and 350 kW or or
frame size < IEC frame size > IEC frame size > IEC
315 315 400
PN < 134 HP 134 HP < PN < PN > 469 HP
and frame size < 469 HP or frame size >
NEMA 500 or frame size > NEMA 580
NEMA 500
N Random- UN < 420 V Standard: ÛLL = - + N or CMF + N + CMF
O wound and 1300 V
N form-wound 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: - + N or CMF + N + CMF
ÛLL = 1600 V,
0.2
microsecond
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: - + N or CMF + N + CMF
ÛLL = 1800 V
600 V < UN < 690 V Reinforced: + du/dt + du/dt + N + du/dt + N + CMF
ÛLL = 1800 V
Reinforced: - N + CMF N + CMF
ÛLL = 2000 V,
0.3
microsecond
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.

45
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 filter at the output of the drive +E205
CMF common mode filter +E208
N N-end bearing: insulated motor non-driven end bearing
n.a. Motors of this power range are not available as standard units. Consult the motor manufacturer.
Note 2: Explosion-safe (Ex) motors

The motor manufacturer should be consulted regarding the construction of the motor insulation and
additional requirements for explosion-safe (Ex) motors.
Note 3: High-output motors and IP23 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
200 kW
PN < 74 HP 74 HP < PN < PN > 268 HP
268 HP
A Random- UN < 500 V Standard - +N + N + CMF
B wound M3AA, 500 V < U < 600 V Standard + du/dt + du/dt + N + du/dt + N + CMF
N
B M3AP, M3BP
or
Reinforced - +N + N + CMF
600 V < 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 20
percent. The voltage increase should be taken into consideration when determining the motor insulation
requirement.
Example: Motor insulation requirement for a 400 V application must be selected as if the drive were
supplied with 480 V.

46
Note 7: 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
the values of the graph by the supply voltage (UN).With resistor braking, the ÛLL and du/dt values are
approximately 20 % higher.
3.0 5.5
ÛLL/UN 5.0
2.5 du/dt
------------- (1/μs)
4.5 UN
2.0 4.0
3.5
1.5
3.0
ÛLL/UN
1.0 2.5
du/dt
------------- (1/μs)
UN 2.0
0.5
1.5
0.0 1.0
100 200 300 100 200 300
Cable length (m) Cable length (m)
With du/dt filter Without du/dt filter
Note 8: Sine filters protect the motor insulation system. Therefore, du/dt filter can be replaced with
a sine filter. The peak phase-to-phase voltage with the sine filter is approximately 1.5 × UN.
Note 9: Common mode filter is available as a separate kit (one box including three rings for one cable).
Permanent magnet synchronous motor

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

47
Supply connection
Disconnecting device (means)

Install a hand-operated input disconnecting device (disconnecting means) between
the AC power source and the drive. The disconnecting device must be of a type that
can be locked to the open position for installation and maintenance work.
EEA / Europe
If the drive is used in an application which must meet the European Union Machinery
Directive according to standard EN 60204-1 Safety of Machinery, the disconnecting
device must be one of the following types:
• a switch-disconnector of utilization category AC-23B (EN 60947-3)
• a 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)
• a circuit breaker suitable for isolation in accordance with EN 60947-2.
US
The disconnecting means must conform to the applicable safety regulations.
Main contactor
If used, dimension the contactor according to the nominal voltage and current of the
drive. The utilization category (IEC 947-4) is AC-1.
Fuses
See section Thermal overload and short circuit protection.

48
Thermal overload and short circuit protection
Thermal overload protection of the drive and the input and motor cables
The drive protects itself and the input and motor cables against thermal overload
when the cables are dimensioned according to the nominal current of the drive. No
additional thermal protection devices are needed.
WARNING! If the drive is connected to multiple motors, a separate thermal overload

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

According to regulations, the motor must be protected against thermal overload and
the current must be switched off when overload is detected. The drive includes a
motor thermal protection function that protects the motor and switches off the current
when necessary. Depending on a drive parameter value, the function either monitors
a calculated temperature value (based on a motor thermal model) or an actual
temperature indication given by motor temperature sensors. The user can tune the
thermal model further by feeding in additional motor and load data.
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 the motor cable

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

49
Protection against short circuit inside the drive or in the supply cable
Protect the input cable and drive against short-circuit according to the following
guide lines.
Circuit diagram Short-circuit
protection
Protect the drive and
Distribution Drive or drive input cable with fuses
board Input cable module or a circuit breaker.
See footnotes 1) and
1) 2).
~ M
~ 3~
2)
~ M
I>
~ 3~
1) Size the fuses according to instructions given in chapter Technical data. The fuses will protect the input
cable in short-circuit situations, restrict drive damage and prevent damage to adjoining equipment in
case of a short-circuit inside the drive.
2) Circuit breakers which have been tested by ABB with the ACS800 can be used. Fuses must be used
with other circuit breakers. Contact your local ABB representative for approved breaker types and
supply network characteristics.
The protective characteristics of circuit breakers depend on the type, construction and settings of the
breakers. There are also limitations pertaining to the short-circuit capacity of the supply network.
WARNING! Due to the inherent operating principle and construction of circuit breakers,
independent of the manufacturer, hot ionized gases may escape from the breaker
enclosure in case of a short-circuit. To ensure safe use, special attention must be paid to
the installation and placement of the breakers. Follow the manufacturer’s instructions.
Note: Circuit breakers must not be used without fuses in the USA.
Ground fault protection

The drive is equipped with an internal ground fault protective function to protect the
unit against ground faults in the motor and the motor cable. This is not a personal
safety or a fire protection feature. The ground fault protective function can be
disabled with a parameter, refer to the appropriate ACS800 Firmware Manual.
The EMC filter of the drive includes capacitors connected between the main circuit
and the frame. These capacitors and long motor cables increase the ground leakage
current and may cause fault current circuit breakers to function.
Emergency stop devices

For safety reasons, install the emergency stop devices at each operator control
station and at other operating stations where emergency stop may be needed.

50
Note: Pressing the stop key ( ) on the control panel of the drive does not generate
an emergency stop of the motor or separate the drive from dangerous potential.
Prevention of Unexpected Start

The drive can be equipped with an optional Prevention of Unexpected Start function
according to standards IEC/EN 60204-1: 1997; ISO/DIS 14118: 2000 and EN 1037:
1996.
The Prevention of Unexpected Start function disables the control voltage of the
power semiconductors, thus preventing the inverter from generating the AC voltage
required to rotate the motor. By using this function, short-time operations (like
cleaning) and/or maintenance work on non-electrical parts of the machinery can be
performed without switching off the AC power supply to the drive.
The operator activates the Prevention of Unexpected Start function by opening a
switch on a control desk. An indicating lamp on the control desk will light, signalling
that the prevention is active. The switch can be locked out.
A Gate Driver Power Supply board (AGPS) and a 3 m connection wire are delivered
with the Prevention of Unexpected Start option kit. The Prevention of Unexpected
Start function complies with EN954-1 categories 1 and 3 when the following
installations are made:
The user must install on a control desk near the machinery:
• switching/disconnecting device for the circuitry. “Means shall be provided to
prevent inadvertent, and/or mistaken closure of the disconnecting device.”
EN 60204-1: 1997.
• indicating lamp; on = starting the drive is prevented, off = drive is operative.
• safety relay (type BD5935 has been approved by ABB)
(Switching/disconnecting device, indicating lamp and safety relay are not included in
the delivery.)
For connections to the drive, see section Prevention of Unexpected Start, AGPS
board in chapter Electrical installation.
WARNING! The Prevention of Unexpected Start function does not disconnect the
voltage of the main and auxiliary circuits from the drive. Therefore maintenance work
on electrical parts of the drive or the motor can only be carried out after isolating the
drive system from the main supply.
Note: The Prevention of Unexpected Start function is not intended for stopping the
drive. If a running drive is stopped by using the Prevention of Unexpected Start
function, the drive will cut off the motor supply voltage and the motor will coast to
stop.

51
Selecting the power cables
General rules
Dimension the mains (input power) and motor cables according to local
regulations:
• The cable must be able to carry the drive load current. See chapter Technical
data for the rated currents.
• The cable must be rated for at least 70°C maximum permissible temperature of
conductor in continuous use. For US, see section Additional US requirements.
• The inductance and impedance of the PE conductor/cable (grounding wire) must
be rated according to permissible touch voltage appearing under fault conditions
(so that the fault point voltage will not rise excessively when a ground fault
occurs).
• 600 V AC cable is accepted for up to 500 V AC. 750 V AC cable is accepted for
up to 600 V AC. For 690 V AC rated equipment, the rated voltage between the
conductors of the cable should be minimum 1 kV.
For drive frame size R5 and larger, or motors larger than 30 kW (40 HP),
symmetrical shielded motor cable must be used (figure below). A four-conductor
system can be used up to frame size R4 with up to 30 kW (40 HP) motors, but
shielded symmetrical motor cable is always recommended. The shield(s) of motor
cable(s) must have 360° bonding at both ends.
Note: When continuous metal conduit is employed, shielded cable is not required.
The conduit must have bonding at both ends as with cable shield.
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 corresponding
conductors protective conductor
S (mm2) Sp (mm2)
S < 16 S
16 < S < 35 16
35 < S S/2
Compared to a four-conductor system, the use of symmetrical shielded cable

reduces electromagnetic emission of the whole drive system as well as the stress on
motor insulation, bearing currents and wear.
The motor cable and its PE pigtail (twisted shield) should be kept as short as
possible in order to reduce high frequency electromagnetic emission, as well as
stray currents outside the cable and capacitive current (relevant in power range
below 20 kW).

52
Alternative power cable types

Power cable types that can be used with the drive are represented below.
Recommended
Symmetrical shielded cable: three phase conductors A separate PE conductor is required if the conductivity
and a concentric or otherwise symmetrically of the cable shield is < 50% of the conductivity of the
constructed PE conductor, and a shield phase conductor.
PE conductor Shield
and shield Shield
PE
PE
PE Shield
A four-conductor system:
three phase conductors
and a protective
conductor.
Not allowed for motor cables Not allowed for motor cables with phase
conductor cross section larger than 10 mm2
[motors > 30 kW (40 HP)].
Motor cable shield

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

Insulation jacket
Cable core

53
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 V AC cable is accepted for up to
500 V AC. 1000 V AC cable is required above 500 V AC (below 600 V AC). For
drives rated over 100 amperes, the power cables must be rated for 75°C (167°F).
Conduit
Separate parts of a conduit must be coupled together, bridge the joints with a ground
conductor bonded to the conduit on each side of the joint. Bond the conduits also to
the drive enclosure and motor frame. Use separate conduits for input power, motor,
brake resistor, and control wiring. When conduit is employed, type MC continuous
corrugated aluminium armor cable or shielded cable is not required. A dedicated
ground cable is always required.
Note: Do not run motor wiring from more than one drive in the same conduit.
Armored cable / shielded power cable

Six conductor (3 phases and 3 ground) type MC continuous corrugated 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, LAPPKABEL (ÖLFLEX) and
Pirelli.

54
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 or harmonic

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

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

55
Before opening a contactor (DTC control mode selected)

Stop the drive and wait for the motor to stop before opening a contactor between the
output of the drive and the motor when the DTC control mode is selected. See the
appropriate ACS800 Application Program Firmware Manual for the required
parameter settings. Otherwise, the contactor will be damaged. In scalar control, the
contactor can be opened with the drive running.
Protecting the relay output contacts and attenuating disturbances in case

of inductive loads
Inductive loads (relays, contactors, motors) cause voltage transients when switched
off.
The relay contacts on the RMIO board are protected with varistors (250 V) against
overvoltage peaks. In spite of this, it is highly recommended to equip inductive loads
with noise attenuating circuits [varistors, RC filters (AC) or diodes (DC)] in order to
minimize the EMC emission at switch-off. If not suppressed, the disturbances may
connect capacitively or inductively to other conductors in the control cable and form
a risk of malfunction in other parts of the system.
Install the protective component as close to the inductive load as possible. Do not
install protective components at the RMIO board terminal block.
RMIO
Relay outputs
Varistor X25
1 RO1
230 V AC 2 RO1
3 RO1
RC filter X26
1 RO2
230 V AC 2 RO2
3 RO2
Diode X27
1 RO3
24 VD C 2 RO3
3 RO3

56
Selecting the control cables

All control cables must be shielded.
Use a double-shielded twisted pair cable (Figure a, e.g. JAMAK by NK Cables,
Finland) for analogue signals. This type of cable is recommended for the pulse
encoder signals also. Employ one individually shielded pair for each signal. Do not
use common return for different analogue signals.
A double-shielded cable is the best alternative for low-voltage digital signals but
single-shielded twisted multipair cable (Figure b) is also usable.
a b
A double-shielded twisted A 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 V DC and 115/230 V AC signals in the same cable.
Relay cable
The cable type with braided metallic screen (e.g. ÖLFLEX by LAPPKABEL,
Germany) has been tested and approved by ABB.
Control panel cable

In remote use, the cable connecting the control panel to the drive must not exceed
3 metres (10 ft). The cable type tested and approved by ABB is used in control panel
option kits.

57
Connection of a motor temperature sensor to the drive I/O
WARNING! IEC 60664 requires double or reinforced insulation between live parts
and the surface of accessible parts of electrical equipment which are either non-
conductive or conductive but not connected to the protective earth.
To fulfil this requirement, the connection of a thermistor (and other similar
components) to the digital inputs of the drive can be implemented in three alternate
ways:
1. There is double or reinforced insulation between the thermistor and live parts of
the motor.
2. Circuits connected to all digital and analogue inputs of the drive are protected
against contact and insulated with basic insulation (the same voltage level as the
drive main circuit) from other low voltage circuits.
3. An external thermistor relay is used. The insulation of the relay must be rated for
the same voltage level as the main circuit of the drive. For connection, see
ACS800 Firmware Manual.
Installation sites above 2000 metres (6562 feet)
WARNING! Protect against direct contact when installing, operating and servicing
the RMIO board wiring and optional modules attached to the board. The Protective
Extra Low Voltage (PELV) requirements stated in EN 50178 are not fulfilled at
altitudes above 2000 m (6562 ft).
Routing the cables

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

58
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
230 V 230 V
24 V (120 V) 24 V (120 V)
Not allowed unless the 24 V cable is Lead 24 V and 230 V (120 V) control
insulated for 230 V (120 V) or insulated cables in separate ducts inside the
with an insulation sleeving for cabinet.
230 V (120 V).

59

This chapter describes the electrical installation procedure of the drive.
WARNING! The work described in this chapter may only be carried out by a qualified
electrician. Follow the Safety instructions on the first pages of this manual. Ignoring
the safety instructions can cause injury or death.
Make sure that the drive is disconnected from the mains (input power) during
installation. If the drive is already connected to the mains, wait for 5 min after
disconnecting mains power.
Checking the insulation of the assembly
Drive
Do not make any voltage tolerance or insulation resistance tests (e.g. hi-pot or
megger) on any part of the drive as testing can damage the drive. Every drive has
been tested for insulation between the main circuit and the chassis (2500 V rms
50 Hz for 1 second) at the factory. Also, there are voltage-limiting circuits inside the
drive which cut down the testing voltage automatically.
Input cable
Check the insulation of the input cable according to local regulations before
connecting it to the drive.
Motor and motor cable

1. Check that the motor cable is disconnected from the drive output terminals U2,
V2 and W2.
M 2. Measure the insulation resistances of the motor cable and the motor between
ohm each phase and the Protective Earth by using a measuring voltage of 1 kV DC.
PE
The insulation resistance must be higher than 1 Mohm.
60
IT (ungrounded) systems
Ensure that the drive is not equipped with optional EMC filter, i.e. type code does not
include selections +E200 or +E202.
However if EMC filters exist, disconnect the EMC filter capacitors of selections
+E202 and +E200 before connecting the drive to an ungrounded system. For
detailed instructions on how to do this, please contact your local ABB distributor.
WARNING! If a drive with EMC filter selection +E202 or +E200 is installed on an IT

system [an ungrounded power system or a high resistance-grounded (over 30 ohms)
power system], the system will be connected to earth potential through the EMC
filter capacitors of the drive. This may cause danger or damage the unit.
61
Power cable connection
Power cable connection
Drive with brake chopper included

INPUT UDC+ UDC- OUTPUT
PE U1 V1 W1 R- R+ U2 V2 W2
1) 2)
(PE) PE (PE)
3)
V1 W1
U1
External brake
For alternatives, see
Planning the electrical
resistor (360
degrees grounding
3 ~
installation: Motor
required)
Disconnecting device
(means). L1 L2 L3
Connecting the power cables

• Connect the twisted shield of the cable to the drive grounding terminal. Note:
cable lugs are needed in frame sizes R2 and R3.
• Supply cable grounding: If shielded cable is used, and the conductivity of the
shield is < 50% of the conductivity of the phase conductor, use a separate PE
cable (1) or a cable with a grounding conductor (2). With shielded cable 360°
grounding of the supply cables is recommended.
Motor cable grounding: Use a separate grounding cable (3) if the conductivity of
the cable shield is < 50% of the conductivity of the phase conductor and there is
no symmetrically constructed grounding conductor in the cable (see Planning the
electrical installation: Selecting the power cables).
360 degrees grounding is required at the cabinet entry in first environment
installations. First environment EMC compliance is defined in chapter Technical
data.
Note: If there is a symmetrically constructed grounding conductor in the motor
cable in addition to the conductive shield, connect the grounding conductor to the
grounding terminal at the drive and motor ends.
Note: Do not use an asymmetrically constructed motor cable. Connecting its
fourth conductor at the motor end increases bearing currents and causes extra
wear.
62
• Connect the phase conductors of the mains cable to the U1, V1 and W1 terminals
and the phase conductors of the motor cable to the U2, V2 and W2 terminals.
Strip the conductor ends as follows to fit them inside the power cable connection
terminals.
Note: Lead the unstripped cable as close to the terminals as possible. All
unstripped parts must be protected against contact.
Frame size Stripping length
mm in.
R2, R3 10 0.39
R4, R5 16 0.63
R6 28 1.10
• Secure the cables outside the unit mechanically.

• Ground the other end of the input cable shield or PE conductor at the distribution
board.
Grounding the motor cable shield at the motor end
For minimum radio frequency interference ground the cable shield 360 degrees at
the lead-through of the motor terminal box
360 degrees grounding
Conductive gaskets
or ground the cable by twisting the shield as follows: flattened width > 1/5 · length
b > 1/5 · a
b
a
63
Frame sizes R2 to R4
U1 V1 W1 UDC+
R- R+ UDC- U2 V2 W2
PE
PE
Frame size R5
UDC+
PE U1 V1 W1 R- R+ UDC- U2 V2 W2 PE
64
Frame size R6: Cable lug installation [16 to 70 mm2 (6 to 2/0 AWG) cables]
U1 UDC+
U1
U1 V1 W1 R- R+ UDC- U2 V2 W2 Remove the screw terminals.
Fasten the cable lugs to the
remaining bolts with M10
nuts.
Isolate the ends of the cable

lugs with insulating tape or
shrink tube
PE
65
Frame size R6: Cable terminal installation [95 to 185 mm2 (3/0 to 350 AWG) cables]
U1 UDC+
U1
U1 V1 W1 R- R+ UDC- U2 V2 W2
PE a. Connect the cable to the terminal.

b. Connect the terminal to the drive.
WARNING! If the wire size is less than
95 mm2 (3/0 AWG), a cable lug must
be used. A cable of wire size less than
95 mm2 (3/0 AWG) connected to this
terminal will loosen and may damage
the drive.
Power cable protection

Frame size R5
Cover the power cable terminals as follows:
1. Cut holes for the installed cables into the clear plastic shroud.
2. Press the shroud onto the terminals.
1 2
66
Removal of the shroud with a screw driver:
Frame size R6
Cover the power cable terminals as follows:
1. Cut holes for the installed cables into the clear plastic shroud in cable lug
installations.
2. Press the shroud onto the terminals.
View of cable terminal

2 installation
Removal of the shroud by lifting up with a screw driver from the corner:
Warning sticker
There are warning stickers in different languages inside the packing box of the drive.
Attach a warning sticker in the language of your choice onto the plastic skeleton
above the power cable terminals.
67
Connecting the control cables

Connect the control cables as described below. Connect the conductors to the
appropriate detachable terminals of the RMIO board [see chapter Motor control and
I/O board (RMIO)]. Tighten the screws to secure the connection.
Terminals
Location of terminals vary depending on the drive frame size.
Frame sizes R2 to R4
The control cable connection terminals are
exposed when the control panel mounting platform
is turned aside by pulling this knob. Be careful, do Detachable connection terminals (pull up)
not use excess force when pulling.
X39 for control panel cable
(control panel is an option)
I/O cables: Ground the

control cable shields in the
holes with screws. See
section 360 degrees Optional module 1
grounding.
Optional module 2
DDCS communication
option module 3:
RDCO
4
3
2
1
Place the warning

sticker here
Relay outputs
X41 for Prevention of

Unexpected Start (AGPS
board)
68
Frame sizes R5 and R6
View of frame size R6
Control panel X41 for Prevention of

(optional) Unexpected Start (AGPS
board)
Optional module 1 Optional module 2
DDCS communication option module 3: RDCO

Control cable
grounding: see
section 360 Place the warning sticker here
degrees
grounding Detachable connection terminals (pull up)
69
360 degrees grounding
Insulation
4
3
2
1
Double-shielded cable Single-shielded cable
When the outer surface of the shield is covered with non-conductive material
• Strip the cable carefully (do not cut the grounding wire and the shield)
• Turn the shield inside out to expose the conductive surface.
• Wrap the grounding wire around the conductive surface.
• Slide a conductive clamp onto the conductive part.
• Fasten the clamp to the grounding plate with a screw as close as possible to the
terminals where the wires are about to be connected.
Connecting the shield wires

Single shielded cables: Twist the grounding wires of the outer shield and connect
them through the shortest possible route to the nearest grounding hole with a cable
lug and a screw. Double shielded cables: Connect each pair cable shield (twisted
grounding wires) with other pair cable shields of the same cable to the nearest
grounding hole with a cable lug and a screw.
Do not connect shields of different cables to the same cable lug and grounding
screw.
Leave the other end of the shield unconnected or ground it indirectly via a few
nanofarads high-frequency capacitor (e.g. 3.3 nF / 630 V). The shield can also be
grounded directly at both ends if they are in the same ground line with no significant
voltage drop between the end points.
Keep the signal wire pairs twisted as close to the terminals as possible. Twisting the
wire with its return wire reduces disturbances caused by inductive coupling.
70
Cabling of I/O and fieldbus modules
Module
As short as possible
Shield
4
3
2
1
Note: The RDIO module does not

include a terminal for cable shield
grounding. Ground the pair cable
shields here.
Pulse encoder module cabling
As short as
possible
Note1: If the encoder is of
1
2 unisolated type, ground the encoder
3
4 cable at the drive end only. If the
encoder is galvanically isolated
from the motor shaft and the stator
frame, ground the encoder cable
Shield
shield at the drive and the encoder

RTAC end.
Note 2: Twist the pair cable wires.
Wrap copper tape around the

stripped part of the cable under the
clamp. Be careful. Do not cut the
grounding wire. Clamp as close to
the terminals as possible.
71
Installation of optional modules and PC

The optional module (such as fieldbus adapter, I/O extension module and the pulse
encoder interface) is inserted in the optional module slot of the RMIO board (see
section Connecting the control cables) and fixed with two screws. See the
appropriate optional module manual for cable connections.
Fibre optic link

A DDCS fibre optic link is provided via the RDCO optional module for PC tools,
master/follower link, NDIO, NTAC, NAIO and fieldbus adapter modules of type Nxxx.
See RDCO User’s Manual for connections. Observe colouring codes when installing
fibre optic cables. Blue connectors go to blue terminals, and grey connectors to grey
terminals.
When installing multiple modules on the same channel connect them in a ring.
External +24 V power supply for the RMIO board via terminal X34
This section describes how to connect an external +24 V power supply for the RMIO
board via terminal X34. For the current consumption of the RMIO board, see chapter
Motor control and I/O board (RMIO).
Note: External power is easier to supply to the RMIO board via terminal X23, see
chapter Motor control and I/O board (RMIO).
Parameter settings
In Standard Application Program, set parameter 16.09 CTRL BOARD SUPPLY to
EXTERNAL 24V if the RMIO board is powered from an external supply.
Connecting +24 V external power supply

1. Break off the tab covering the +24 VDC power input connector with pliers.
2. Lift the connector upwards.
3. Disconnect the wires from the connector (keep the connector for later use).
4. Isolate the ends of the wires individually with insulating tape.
5. Cover the isolated ends of the wires with insulating tape.
6. Push the wires inside the skeleton.
7. Connect the wires of the +24 V external power supply to the disconnected
connector:
if a two-way connector, + wire to terminal 1 and - wire to terminal 2
if a three-way connector, + wire to terminal 2 and - wire to terminal 3.
8. Plug the connector in.
72
Frame sizes R2 to R4 Frame sizes R5 and R6
X34
4
4
73
5 6 7
RMIO board RMIO board

1 2 3 1 2 3
X34 X34
+ - + -
1 2 1 2 3
8
Connection of a two-way Connection of a three-way

connector connector
74
Prevention of Unexpected Start, AGPS board
WARNING! Dangerous voltages can be present on the AGPS board even when the
115...230 V supply is switched off. Follow the Safety instructions on the first pages of
this manual and the instruction in this section when working on the AGPS board.
Make sure that the drive is disconnected from the mains (input power) and the
115...230 V source for the AGPS board is switched off during installation and
maintenance. If the drive is already connected to the mains, wait for 5 min after
disconnecting mains power.
Connect the optional AGPS board as follows:

• Remove the enclosure cover by undoing the fixing screws (1).
• Ground the bottom plate of the enclosure or via terminal X1:1 of the AGPS board.
• Connect the cable delivered with the kit between terminal block X2 of the AGPS
board (2) and drive terminal block X41.
• Connect a cable between connector X1 of the AGPS board (3) and the
115...230 V source.
• Fasten the enclosure cover back with screws.
X2
X1
115...230 V
3
75
Note: Location of the X41 terminal block varies according to the drive frame size.
Note: Maximum cable length between AGPS terminal block X2 and drive terminal
block is restricted to 10 m.
For technical data see section AGPS-11C in chapter Technical data.
76
The following figure presents the circuit diagram of the Prevention of Unexpected
Start.
3AFE00374994
77

This chapter shows
• external control connections to the RMIO board for the ACS800 Standard
Application Program (Factory Macro)
• specifications of the inputs and outputs of the board.
This chapter applies to ACS800 units which employ RMIO-01 board from revision J
onwards and RMIO-02 board from revision H onwards.
Note on terminal labelling

Optional modules (Rxxx) may have identical terminal designations with the RMIO
board.
Note on external power supply

External +24 V power supply for the RMIO board is recommended if
• the application requires a fast start after connecting the input power supply
• fieldbus communication is required when the input power supply is disconnected.
The RMIO board can be supplied from an external power source via terminal X23 or
X34 or via both X23 and X34. The internal power supply to terminal X34 can be left
connected when using terminal X23.
WARNING! If the RMIO board is supplied from an external power source via
terminal X34, the loose end of the cable removed from the RMIO board terminal
must be secured mechanically to a location where it cannot come into contact with
electrical parts. If the screw terminal plug of the cable is removed, the wire ends
must be individually insulated.
Parameter settings
In Standard Application Program, set parameter 16.09 CTRL BOARD SUPPLY to
EXTERNAL 24V if the RMIO board is powered from an external supply.

78
External control connections (non-US)

External control cable connections to the RMIO board for the ACS800 Standard
Application Program (Factory Macro) are shown below. For external control
connections of other application macros and programs, see the appropriate
Firmware Manual.
X20
Terminal block size: 1 VREF- Reference voltage -10 VDC, 1 kohm < RL <
cables 0.3 to 3.3 mm2 (22 to 12 AWG) 2 AGND 10 kohm
Tightening torque: X21
0.2 to 0.4 Nm (0.2 to 0.3 lbf ft) 1 VREF+ Reference voltage 10 VDC, 1 kohm < RL <
2 AGND 10 kohm
3 AI1+ Speed reference 0(2) ... 10 V, Rin >
4 AI1- 200 kohm
5 AI2+ By default, not in use. 0(4) ... 20 mA, Rin =
6 AI2- 100 ohm
8 AI3- 100 ohm
rpm 9 AO1+ Motor speed 0(4)...20 mA = 0...motor nom.
10 AO1- speed, RL < 700 ohm
A 11 AO2+ Output current 0(4)...20 mA = 0...motor
12 AO2- nom. current, RL < 700 ohm
X22
1 DI1 Stop/Start
1) Only
effective if par. 10.03 is set to 2 DI2 Forward/Reverse 1)
REQUEST by the user. 3 DI3 Not in use
4 DI4 Acceleration & deceleration select 2)
2)
0 = open, 1 = closed 5 DI5 Constant speed select 3)
DI4 Ramp times according to 6 DI6 Constant speed select 3)
0 parameters 22.02 and 22.03 7 +24VD +24 VDC max. 100 mA
1 parameters 22.04 and 22.05 8 +24VD
9 DGND1 Digital ground
3) See par. group 12 CONSTANT SPEEDS. 10 DGND2 Digital ground
DI5 DI6 Operation 11 DIIL Start interlock (0 = stop) 4)
0 0 Set speed through AI1 X23
1 0 Constant speed 1 1 +24V Auxiliary voltage output and input, non-
0 1 Constant speed 2 2 GND isolated, 24 VDC 250 mA 5)
1 1 Constant speed 3 X25
1 RO1 Relay output 1: ready
4)
See parameter 21.09 START INTRL 2 RO1
FUNC. 3 RO1
5) Total maximum current shared
X26
between this output and optional 1 RO2 Relay output 2: running
modules installed on the board.
2 RO2
3 RO2
X27
1 RO3 Relay output 3: fault (-1)
Fault 2 RO3
3 RO3

79
External control connections (US)

External control cable connections to the RMIO board for the ACS800 Standard
Application Program (Factory Macro US version) are shown below. For external
control connections of other application macros and programs, see the appropriate
Firmware Manual.
X20
Terminal block size: 1 VREF- Reference voltage -10 VDC, 1 kohm < RL <
2
cables 0.3 to 3.3 mm (22 to 12 AWG) 2 AGND 10 kohm
Tightening torque: X21
0.2 to 0.4 Nm (0.2 to 0.3 lbf ft) 1 VREF+ Reference voltage 10 VDC, 1 kohm < RL <
2 AGND 10 kohm
3 AI1+ Speed reference 0(2) ... 10 V, Rin >
4 AI1- 200 kohm
6 AI2- 100 ohm
8 AI3- 100 ohm
rpm 9 AO1+ Motor speed 0(4)...20 mA = 0...motor nom.
10 AO1- speed, RL < 700 ohm
A 11 AO2+ Output current 0(4)...20 mA = 0...motor
12 AO2- nom. current, RL < 700 ohm
X22
1 DI1 Start ( )
1)
Only effective if par. 10.03 is set to 2 DI2 Stop ( )
REQUEST by the user. 3 DI3 Forward/Reverse 1)
4 DI4 Acceleration & deceleration select 2)
2)
0 = open, 1 = closed 5 DI5 Constant speed select 3)
DI4 Ramp times according to 6 DI6 Constant speed select 3)
0 parameters 22.02 and 22.03 7 +24VD +24 VDC max. 100 mA
1 parameters 22.04 and 22.05 8 +24VD
9 DGND1 Digital ground
3) See par. group 12 CONSTANT 10 DGND2 Digital ground
SPEEDS. 11 DIIL Start interlock (0 = stop) 4)
DI5 DI6 Operation X23
0 0 Set speed through AI1 1 +24V Auxiliary voltage output and input, non-
1 0 Constant speed 1
2 GND isolated, 24 VDC 250 mA 5)
X25
1 RO1 Relay output 1: ready
4) 2 RO1
See parameter 21.09 START INTRL
3 RO1
FUNC.
5) Total maximum current shared X26
between this output and optional 1 RO2 Relay output 2: running
modules installed on the board. 2 RO2
3 RO2
X27
1 RO3 Relay output 3: fault (-1)
Fault 2 RO3
3 RO3

80
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 (without any optional modules inserted onto slots 1 and 2)
Analogue outputs
Two programmable current outputs: 0 (4) to 20 mA, RL < 700 ohm
Resolution 0.1% (10 bit)
Inaccuracy ±1% (Full Scale Range) at 25°C (77°F). Temperature coefficient: ±200 ppm/°C
(±111 ppm/°F) max.
Digital inputs
With 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

81
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
Contact material Silver Cadmium Oxide (AgCdO)
Isolation test voltage 4 kVAC, 1 minute
DDCS fibre optic link

With optional communication adapter module RDCO. Protocol: DDCS (ABB
Distributed Drives Communication System)
24 VDC power input
Voltage 24 VDC ±10%
Typical current consumption 250 mA
(without optional modules)
Maximum current consumption 1200 mA (with optional modules inserted)
The terminals on the RMIO board as well as on the optional modules attachable to the board fulfil the Protective Extra
Low Voltage (PELV) requirements stated in EN 50178 provided that the external circuits connected to the terminals also
fulfil the requirements and the installation site is below 2000 m (6562 ft). Above 2000 m (6562 ft), see page 57.

82
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
5 AI2+ voltage between
6 AI2- channels ±15 V
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

J1
6 DI6 common ground. This is the
7 +24VD default setting.
8 +24VD
11 DIIL
10 DGND2
X23 Grounds of input
1 +24 V or groups DI1…DI4 and
2 GND DI5/DI6/DIIL are
X25 separate (isolation
voltage 50 V).
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

83
Checklist
Check the mechanical and electrical installation of the drive before start-up. Go
through the checklist below together with another person. Read the Safety
instructions on the first pages of this manual before you work on the unit.
Check
MECHANICAL INSTALLATION
The ambient operating conditions are allowed. (See Mechanical installation, Technical data:
IEC data or NEMA data, Ambient conditions.)
The unit is fixed properly into the cabinet. (See Planning the cabinet assembly and
Mechanical installation.)
The cooling air will flow freely.
The motor and the driven equipment are ready for start. (See Planning the electrical
installation: Motor selection and compatibility, Technical data: Motor connection.)
ELECTRICAL INSTALLATION (See Planning the electrical installation, Electrical installation.)
Drive does not include the EMC filter option (+E202, +E200) or the +E202 and +E200 EMC
filter capacitors are disconnected if the drive is connected to an IT (ungrounded) system.
The capacitors are reformed if stored over one year (refer to ACS600/800 Capacitor
Reforming Guide [3AFE64059629 (English)].
The drive is grounded properly.
The mains (input power) voltage matches the drive nominal input voltage.
The mains (input power) connections at U1, V1 and W1 and their tightening torques are OK.
Appropriate mains (input power) fuses and disconnector are installed.
The motor connections at U2, V2 and W2 and their tightening torques are OK.
The motor cable is routed away from other cables.
There are no power factor compensation capacitors in the motor cable.
The external control connections inside the drive are OK.
There are no tools, foreign objects or dust from drilling inside the drive.
Mains (input power) voltage cannot be applied to the output of the drive (with bypass
connection).
Motor connection box and other covers are in place.
84
Check
Modules with prevention of unexpected start option only (AGPS board): The prevention of
unexpected start circuit is completed.
85
Maintenance

This chapter contains preventive maintenance instructions.
Safety
WARNING! Read the Safety instructions on the first pages of this manual before
performing any maintenance on the equipment. Ignoring the safety instructions can
cause injury or death.
Maintenance intervals
If installed in an appropriate environment, the drive requires very little maintenance.
This table lists the routine maintenance intervals recommended by ABB.
Maintenance Interval Instruction
Capacitor reforming Every year when stored See Reforming.
Heatsink temperature check Depends on the dustiness of See Heatsink.

and cleaning the environment (every 6 to 12
months)
Change of additional cooling Every three years See Additional fan.

fan.
Cooling fan change Every six years See Fan.
Frame size R4 and up: Every ten years See Capacitors.

capacitor change
Heatsink
The heatsink fins pick up dust from the cooling air. The drive runs into
overtemperature warnings and faults if the heatsink is not clean. In a “normal”
environment (not dusty, not clean) the heatsink should be checked annually, in a
dusty environment more often.
Clean the heatsink as follows (when necessary):
1. Remove the cooling fan (see section Fan).
2. Blow clean compressed air (not humid) from bottom to top and simultaneously
use a vacuum cleaner at the air outlet to trap the dust. Note: If there is a risk of
the dust entering adjoining equipment, perform the cleaning in another room.
3. Replace the cooling fan.
Maintenance
86
Fan
The cooling fan lifespan of the drive is about 50 000 operating hours. The actual
lifespan depends on the drive usage and ambient temperature. See the appropriate
ACS800 Firmware Manual for an actual signal which indicates the hours of usage of
the fan. For resetting the running time signal after a fan replacement, please contact
ABB.
Fan failure can be predicted by the increasing noise from fan bearings and the
gradual rise in the heatsink temperature in spite of heatsink cleaning. If the drive is
operated in a critical part of a process, fan replacement is recommended once these
symptoms start appearing. Replacement fans are available from ABB. Do not use
other than ABB specified spare parts.
Fan replacement (R2, R3)

To remove the fan, release the retaining clips. Disconnect the cable. Install the new
fan in reverse order.
Bottom view
Maintenance
87
Fan replacement (R4)

1. Loosen the screws that fasten the fan mounting plate to the frame.
2. Push the fan mounting plate to the left and pull it out.
3. Disconnect the fan power cable.
4. Undo the screws that fasten the fan to the fan mounting plate.
5. Install the new fan in reverse order.
1 1 Bottom view
2
3
View from above fan
plate pulled out
4 4
4 4
Maintenance
88

1. Undo the fastening screws of the swing-out frame.
2. Open the swing-out frame.
3. Disconnect the cable.
4. Undo the fastening screws of the fan.
5. Install the new fan in reverse order.
Bottom view
4 4 2
Maintenance
89

To remove the fan, undo the fixing screws. Disconnect the cable. Install the new fan
in reverse order.
Bottom view
Additional fan
In ACS800-04/U4 (R2...R6) units there is an additional fan in all types except in
-0001-2, -0002-2, -0003-2, -0003-3, -0004-3, -0005-3, -0004-5, -0005-5 and
-0006-5.
Replacement (R2, R3)

To remove the fan, release the retaining clip (1). Disconnect the cable (2, detachable
terminal). Install the new fan in reverse order.
Air flow upwards

1
2
Rotation direction
View from above
Maintenance
90
Replacement (R4, R5)

The fan is located on the lower right-hand side of the unit (R4) or on the right-hand
side of the control panel (R5). Lift the fan out and disconnect the cable. Install the fan
in reverse order.
Replacement (R6)
To remove the fan, release the retaining clips by pulling the back edge (1) of the fan
upwards. Disconnect the cable (2, detachable terminal). Install the new fan in
reverse order.
Air flow upwards
Rotation direction
2 View from above

1
Capacitors
The drive intermediate circuit employs several electrolytic capacitors. Their lifespan
is from 45 000 to 90 000 hours depending on drive loading and ambient
temperature. Capacitor life can be prolonged by lowering the ambient temperature.
It is not possible to predict a capacitor failure. Capacitor failure is usually followed by
a mains fuse failure or a fault trip. Contact ABB if capacitor failure is suspected.
Replacements for frame size R4 and up are available from ABB. Do not use other
than ABB specified spare parts.
Reforming
Reform (re-age) spare part capacitors once a year according to ACS600/800
Capacitor Reforming Guide [3AFE64059629 (English)].
LEDs
This table describes LEDs of the drive.
Where LED When the LED is lit
RMIO board Red Drive in fault state

Green The power supply on the board is OK.
Maintenance
91
Technical data

This chapter contains the technical specifications of the drive, e.g. the ratings, sizes
and technical requirements, provisions for fulfilling the requirements for CE and
other markings and warranty policy.
IEC data
Ratings
The IEC ratings for the ACS800-04 with 50 Hz and 60 Hz supplies are given below.
The symbols are described below the table.
ACS800-04 size Nominal No-overload Light-overload Heavy-duty use Frame Air Heat
ratings use use size flow dissipation
Icont.max Imax Pcont.max I2N PN I2hd Phd
A kW
A A kW A kW m3/h W
Three-phase supply voltage 208 V, 220 V, 230 V or 240 V
-0001-2 5.1 6.5 1.1 4.7 0.75 3.4 0.55 R2 35 100
-0002-2 6.5 8.2 1.5 6.0 1.1 4.3 0.75 R2 35 100
-0003-2 8.5 10.8 1.5 7.7 1.5 5.7 1.1 R2 35 100
-0004-2 10.9 13.8 2.2 10.2 2.2 7.5 1.5 R2 35 120
-0005-2 13.9 17.6 3 12.7 3 9.3 2.2 R2 35 140
-0006-2 19 24 4 18 4 14 3 R3 69 160
-0009-2 25 32 5.5 24 5,5 19 4 R3 69 200
-0011-2 34 46 7.5 31 7.5 23 5.5 R3 69 250
-0016-2 44 62 11 42 11 32 7.5 R4 103 340
-0020-2 55 72 15 50 11 37 7.5 R4 103 440
-0025-2 72 86 18.5 69 18.5 49 11 R5 250 530
-0030-2 86 112 22 80 22 60 15 R5 250 610
-0040-2 103 138 30 94 22 69 18.5 R5 250 810
-0050-2 141 164 37 132 37 97 30 R6 405 1190
-0060-2 166 202 45 155 45 115 30 R6 405 1190
-0070-2 202 282 55 184 55 141 37 R6 405 1440
Technical data
92
A kW
A A kW A kW m3/h W
Three-phase supply voltage 380 V, 400 V or 415 V
-0003-3 5.1 6.5 1.5 4.7 1.5 3.4 1.1 R2 35 100
-0004-3 6.5 8.2 2.2 5.9 2.2 4.3 1.5 R2 35 120
-0005-3 8.5 10.8 3 7.7 3 5.7 2.2 R2 35 140
-0006-3 10.9 13.8 4 10.2 4 7.5 3 R2 35 160
-0009-3 13.9 17.6 5.5 12.7 5.5 9.3 4 R2 35 200
-0011-3 19 24 7.5 18 7.5 14 5.5 R3 69 250
-0016-3 25 32 11 24 11 19 7.5 R3 69 340
-0020-3 34 46 15 31 15 23 11 R3 69 440
-0023-3 40 46 22 39 18.5 28 15 R3 69 520
-0025-3 44 62 22 41 18.5 32 15 R4 103 530
-0030-3 55 72 30 50 22 37 18.5 R4 103 610
-0035-3 59 72 30 57 30 41 22 R4 103 660
-0040-3 72 86 37 69 30 49 22 R5 168 810
-0050-3 86 112 45 80 37 60 30 R5 168 990
-0060-3 103 138 55 100 55 69 37 R5 168 1190
-0070-3 141 164 75 132 55 97 45 R6 405 1440
-0100-3 166 202 90 155 75 115 55 R6 405 1940
-0120-3 202 282 110 184 90 141 75 R6 405 2310
-0135-3 225 326 110 220 110 163 90 R6 405 2810
-0165-3 260 326 132 254 132 215 110 R6 405 3260
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V
-0004-5 4.9 6.5 2.2 4.5 2.2 3.4 1.5 R2 35 120
-0005-5 6.2 8.2 3 5.6 3 4.2 2.2 R2 35 140
-0006-5 8.1 10.8 4 7.7 4 5.6 3 R2 35 160
-0009-5 10.5 13.8 5.5 10 5.5 7.5 4 R2 35 200
-0011-5 13.2 17.6 7.5 12 7.5 9.2 5.5 R2 35 250
-0016-5 19 24 11 18 11 13 7.5 R3 69 340
-0020-5 25 32 15 23 15 18 11 R3 69 440
-0025-5 34 46 18.5 31 18.5 23 15 R3 69 530
-0028-5 38 46 22 37 22 27 18.5 R3 69 590
-0030-5 42 62 22 39 22 32 18.5 R4 103 610
-0040-5 48 72 30 44 30 36 22 R4 103 810
-0045-5 56 72 37 54 37 39 22 R4 103 950
-0050-5 65 86 37 61 37 50 30 R5 168 990
-0060-5 79 112 45 75 45 60 37 R5 168 1190
-0070-5 96 138 55 88 55 69 45 R5 168 1440
-0100-5 124 164 75 115 75 88 55 R6 405 1940
-0120-5 157 202 90 145 90 113 75 R6 405 2310
-0140-5 180 282 110 163 110 141 90 R6 405 2810
-0165-5 225 326 132 220 132 163 110 R6 405 3260
-0205-5 260 326 160 254 160 215 132 R6 405 3800
Technical data
93
A kW
A A kW A kW m3/h W
Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V or 690 V
-0011-7 13 14 11 11.5 7.5 8.5 5.5 R4 103 300
-0016-7 17 19 15 15 11 11 7.5 R4 103 340
-0020-7 22 28 18.5 20 15 15 11 R4 103 440
-0025-7 25 38 22 23 18.5 19 15 R4 103 530
-0030-7 33 44 30 30 22 22 18.5 R4 103 610
-0040-7 36 54 30 34 30 27 22 R4 103 690
-0050-7 51 68 45 46 37 34 30 R5 250 840
-0060-7 57 84 55 52 45 42 37 R5 250 1010
-0070-7 79 104 75 73 55 54 45 R6 405 1220
-0100-7 93 124 90 86 75 62 55 R6 405 1650
-0120-7 113 172 110 108 90 86 75 R6 405 1960
-0145-7 134 190 132 125 110 95 90 R6 405 2660
-0175-7 166 245 160 155 132 131 110 R6 405 3470
-0205-7 190 245 160 180 160 147 132 R6 405 4180
PDM code: 00096931-J
Symbols
Nominal ratings
Icont.max continuous rms output current. No overload capability at 40°C.
Imax maximum output current. Available for 10 s at start, otherwise as long as allowed by drive
temperature.
Typical ratings:
No-overload use
Pcont.max typical motor power. The power ratings apply to most IEC 34 motors at the nominal voltage,
230 V, 400 V, 500 V or 690 V.
Light-overload use (10% overload capability)
I2N continuous rms current. 10% overload is allowed for one minute every 5 minutes.
PN typical motor power. The power ratings apply to most IEC 34 motors at the nominal voltage,
230 V, 400 V, 500 V or 690 V.
Heavy-duty use (50% overload capability)
I2hd continuous rms current. 50% overload is allowed for one minute every 5 minutes.
Phd typical motor power. The power ratings apply to most IEC 34 motors at the nominal voltage,
230 V, 400 V, 500 V or 690 V.
Sizing
The current ratings are the same regardless of the supply voltage within one voltage range. To achieve
the rated motor power given in the table, the rated current of the drive must be higher than or equal to
the rated motor current.
Note 1: The maximum allowed motor shaft power is limited to 1.5 · Phd, 1.1 · PN or Pcont.max (whichever
value is greatest). If the limit is exceeded, motor torque and current are automatically restricted. The
function protects the input bridge of the drive against overload. If the condition exists for 5 minutes, the
limit is set to Pcont.max.
Note 2: The ratings apply in ambient temperature of 40°C (104°F). In lower temperatures the ratings
are higher (except Imax).
Note 3: Use the DriveSize PC tool for a more accurate dimensioning if the ambient temperature is
below 40°C (104°F) or the drive is loaded cyclically.
Technical data
94
Derating
The load capacity (current and power) decreases if the installation site altitude exceeds 1000 metres
(3300 ft), or if the ambient temperature exceeds 40°C (104°F).
Temperature derating
In the temperature range +40°C (+104°F) to +50°C (+122°F) the rated output current is decreased by
1% for every additional 1°C (1.8°F). The output current is calculated by multiplying the current given in
the rating table by the derating factor.
Example If the ambient temperature is 50°C (+122°F), the derating factor is 100% - 1 % · 10°C =
90% or 0.90. The output current is then 0.90 · I or 0.90 · I . °C
2N 2hd
Altitude derating
In altitudes from 1000 to 4000 m (3300 to 13123 ft) above sea level, the derating is 1% for every 100 m
(328 ft). For a more accurate derating, use the DriveSize PC tool.
Cooling characteristics
ACS800-04 Minimum effective area of air inlet Minimum effective area of air outlet
frame size cm2 cm2
IP22 cabinet IP54 cabinet IP22 cabinet IP54 cabinet
R2 125 250 200 400
R3 250 500 400 800
R4 375 750 600 1200
R5 500 1000 800 1600
R6 1000 2000 1600 3200
Cooling requirements for flange mounting
ACS800-04 Air flow: drive front side Air flow: heat sink side
frame size m3/h m3/h
R2 18 35
R3 30 69
R4 30 103
R5 30 168
R6 30 405
Technical data
95
Mains cable fuses

Fuses for short circuit protection of the mains cable are listed below. The fuses also
protect the adjoining equipment of the drive in case of a short circuit. Check that the
operating time of the fuse is below 0.5 seconds. The operating time depends on
the supply network impedance and the cross-sectional area and length of the supply
cable. See also chapter Planning the electrical installation. For UL recognized fuses,
see section NEMA data.
Note 1: In multicable installations, install only one fuse per phase (not one fuse per conductor).
Note 2: Larger fuses must not be used.
Note 3: Fuses from other manufacturers can be used if they meet the ratings.
gG fuses
ACS800-04 size Input Fuse

current A A2s * V Manufacturer Type IEC size
-0001-2 4.4 10 483 500 ABB Control OFAF000H10 000
-0005-2 12 16 993 500 ABB Control OFAF000H16 000
Technical data
96

Technical data
97

-0011-7 12 16 1100 690 ABB Control OFAA000GG16 000
PDM code:00096931-J
* maximum total I2t value for 550 V
Technical data
98
Cable types
The table below gives copper and aluminium cable types for different load currents.
Cable sizing is based on max. 9 cables laid on a cable ladder side by side, ambient
temperature 30°C, PVC insulation, surface temperature 70°C (EN 60204-1 and
IEC 60364-5-2/2001). For other conditions, size the cables according to local safety
regulations, appropriate input voltage and the load current of the drive.
Copper cables with concentric Aluminium cables with concentric
copper shield copper shield
Max. load current Cable type Max. load current Cable type
A mm2 A mm2
14 3x1.5 61 3x25
20 3x2.5 75 3x35
27 3x4 91 3x50
34 3x6 117 3x70
47 3x10 143 3x95
62 3x16 165 3x120
79 3x25 191 3x150
98 3x35 218 3x185
119 3x50 257 3x240
153 3x70 274 3 x (3x50)
186 3x95 285 2 x (3x95)
215 3x120
249 3x150
284 3x185
PDM code: 00096931
Technical data
99
Cable entries
Brake resistor, mains and motor cable terminal sizes (per phase) and tightening
torques are given below.
Frame U1, V1, W1, U2, V2, W2, R+, R- Earthing PE
size Maximum wire size Tightening torque Maximum wire size Tightening torque
mm2 Nm mm2 Nm
R2 up to 16 * 1.2...1.5 up to 10 1.5
R3 up to 16 * 1.2...1.5 up to 10 1.5
R4 up to 25 2…4 up to 16 3.0
R5 6...70 15 6...70 15
R6 95...185 ** 20...40 95 8
* 16 mm2 rigid solid cable, 10 mm2 flexible stranded cable

** with cable lugs 16...70 mm2, tightening torque 20...40 Nm. Cable lugs are not included in the delivery.
See page 64.
Dimensions, weights and noise

Frame size Height Width Depth* Weight Noise
mm mm mm kg dB
R2 370 165 193...226 8 62
R3 420 173 231.5...265 13 62
R4 490 240 252.2...271.5 24 62
R5 602 265 275.5 32 65
R6 700 300 399 64 65
* Depth depends on the options included in the drive.
Technical data
100
NEMA data
Ratings
The NEMA ratings for the ACS800-U4 with 60 Hz supplies are given below. The
symbols are described below the table. For sizing, derating and 50 Hz supplies, see
section IEC data.
ACS800-U4 size Imax Normal use Heavy-duty use Frame Air flow Heat
size dissipation
I2N PN I2hd Phd
A A HP A HP ft3/min BTU/Hr
-0002-2 8.2 6.6 1.5 4.6 1 R2 21 350
-0003-2 10.8 8.1 2 6.6 1.5 R2 21 350
-0004-2 13.8 11 3 7.5 2 R2 21 410
-0006-2 24 21 5 13 3 R3 41 550
-0009-2 32 27 7.5 17 5 R3 41 680
-0011-2 46 34 10 25 7.5 R3 41 850
-0016-2 62 42 15 31 10 R4 61 1150
-0020-2 72 54 20 * 42 15 ** R4 61 1490
-0025-2 86 69 25 54 20 ** R5 147 1790
-0030-2 112 80 30 68 25 ** R5 147 2090
-0040-2 138 104 40 * 80 30 ** R5 147 2770
-0050-2 164 132 50 104 40 R6 238 3370
-0060-2 202 157 60 130 50 ** R6 238 4050
-0070-2 282 192 75 154 60 ** R6 238 4910
-0004-5 6.5 4.9 3 3.4 2 R2 21 410
-0005-5 8.2 6.2 3 4.2 2 R2 21 480
-0006-5 10.8 8.1 5 5.6 3 R2 21 550
-0009-5 13.8 11 7.5 8.1 5 R2 21 690
-0011-5 17.6 14 10 11 7.5 R2 21 860
-0016-5 24 21 15 15 10 R3 41 1150
-0020-5 32 27 20 21 15 R3 41 1490
-0025-5 46 34 25 27 20 R3 41 1790
-0030-5 62 42 30 34 25 R4 61 2090
-0045-5 72 54 40 39 30 R4 61 2770
-0050-5 86 65 50 52 40 R5 147 3370
-0060-5 112 79 60 65 50 R5 147 4050
-0070-5 138 96 75 77 60 R5 147 4910
-0100-5 164 124 100 96 75 R6 238 6610
-0120-5 202 157 125 124 100 R6 238 7890
-0140-5 282 180 150 156 125 R6 238 9600
-0205-5 326 254 200 215 150 R6 238 12980
-0011-7 14 11.5 10 8.5 7.5 R4 61 1050
-0016-7 19 15 10 11 10 R4 61 1200
-0020-7 28 20 15/20*** 15 15** R4 61 1550
-0025-7 38 23 20 20 20** R4 61 1850
-0030-7 44 30 25/30*** 25 25** R4 61 2100
-0040-7 54 34 30 30 30** R4 61 2400
-0050-7 68 46 40 40 40** R5 147 2900
-0060-7 84 52 50 42 40 R5 147 3450
-0070-7 104 73 60 54 50 R6 238 4200
-0100-7 124 86 75 62 60 R6 238 5650
-0120-7 172 108 100 86 75 R6 238 6700
-0145-7 190 125 125 99 100 R6 238 9100
Technical data
101
ACS800-U4 size Imax Normal use Heavy-duty use Frame Air flow Heat
size dissipation
I2N PN I2hd Phd
A A HP A HP ft3/min BTU/Hr
-0175-7 245 155 150 131 125 R6 238 11900
-0205-7 245 192 200 147 150 R6 238 14300
*
Overload may be limited to 5% at high speeds (> 90% speed) by the internal power limit of the drive.
The limitation also depends on motor characteristics and network voltage.
**
Overload may be limited to 40% at high speeds (> 90% speed) by the internal power limit of the
drive. The limitation also depends on motor characteristics and network voltage.
*** Higher rating is available with special 4-pole high-efficiency NEMA motor.
Symbols
Nominal ratings
Imax maximum output current. Available for 10 s at start, otherwise as long as allowed by drive
temperature.
Normal use (10% overload capability)
I2N continuous rms current. 10% overload is typically allowed for one minute every 5 minutes.
PN typical motor power. The power ratings apply to most 4-pole NEMA rated motors (230 V,
460 V or 575 V).
Heavy-duty use (50% overload capability)
I2hd continuous rms current. 50% overload is typically allowed for one minute every 5 minutes.
Phd typical motor power. The power ratings apply to most 4-pole NEMA rated motors (230 V,
460 V or 575 V).
Note 1: The ratings apply in ambient temperature of 40°C (104°F). In lower temperatures the ratings
are higher (except Imax).
Input cable fuses

The ratings of UL listed fuses for input cable protection are listed below. The fuses
also prevent damage to the adjoining equipment of the drive in case of a short circuit
inside the drive. Check that the operating time of the fuse is below 0.5 seconds.
The operating time depends on the supply network impedance and the cross-
sectional area and length of the supply cable. Fast acting class T or faster fuses are
recommended in the USA. See also Planning the electrical installation: Thermal
overload and short circuit protection.
Note 1: In multicable installations, install only one fuse per phase (not one fuse per conductor).
Note 2: Larger fuses must not be used.
Note 3: Fuses from other manufacturers can be used if they meet the ratings.
Technical data
102
ACS800-U4 type Input Fuse

current
A A V Manufacturer Type UL class
-0002-2 5.2 10 600 Bussmann JJS-10 T
-0003-2 6.5 10 600 Bussmann JJS-10 T
-0004-2 9.2 15 600 Bussmann JJS-15 T
-0006-2 18 25 600 Bussmann JJS-25 T
-0009-2 24 30 600 Bussmann JJS-30 T
-0011-2 31 40 600 Bussmann JJS-40 T
-0016-2 38 50 600 Bussmann JJS-50 T
-0020-2 49 70 600 Bussmann JJS-70 T
-0025-2 64 90 600 Bussmann JJS-90 T
-0030-2 75 100 600 Bussmann JJS-100 T
-0040-2 102 125 600 Bussmann JJS-125 T
-0050-2 126 175 600 Bussmann JJS-175 T
-0060-2 153 200 600 Bussmann JJS-200 T
-0070-2 190 250 600 Bussmann JJS-250 T
-0004-5 4.1 10 600 Bussmann JJS-10 T
-0005-5 5.4 10 600 Bussmann JJS-10 T
-0006-5 6.9 10 600 Bussmann JJS-10 T
-0009-5 9.8 15 600 Bussmann JJS-15 T
-0011-5 13 20 600 Bussmann JJS-20 T
-0016-5 18 25 600 Bussmann JJS-25 T
-0020-5 24 35 600 Bussmann JJS-35 T
-0025-5 31 40 600 Bussmann JJS-40 T
-0030-5 40 50 600 Bussmann JJS-50 T
-0045-5 54 70 600 Bussmann JJS-70 T
-0050-5 63 80 600 Bussmann JJS-80 T
-0060-5 77 100 600 Bussmann JJS-100 T
-0070-5 94 125 600 Bussmann JJS-125 T
-0100-5 121 150 600 Bussmann JJS-150 T
-0120-5 155 200 600 Bussmann JJS-200 T
-0140-5 179 225 600 Bussmann JJS-225 T
-0205-5 243 350 600 Bussmann JJS-350 T
Three-phase supply voltage 525 V, 575 V, 600 V
-0011-7 10 20 600 Bussmann JJS-20 T
-0016-7 13 20 600 Bussmann JJS-20 T
-0020-7 19 30 600 Bussmann JJS-30 T
-0025-7 21 30 600 Bussmann JJS-30 T
-0030-7 29 45 600 Bussmann JJS-45 T
-0040-7 32 45 600 Bussmann JJS-45 T
-0050-7 45 70 600 Bussmann JJS-70 T
-0060-7 51 80 600 Bussmann JJS-80 T
-0070-7 70 100 600 Bussmann JJS-100 T
-0100-7 82 125 600 Bussmann JJS-125 T
-0120-7 103 150 600 Bussmann JJS-150 T
-0145-7 121 200 600 Bussmann JJS-200 T
-0175-7 150 200 600 Bussmann JJS-200 T
-0205-7 188 250 600 Bussmann JJS-250 T
Technical data
103
Cable types
Cable sizing is based on NEC Table 310-16 for copper wires, 75°C (167°F) wire insulation at 40°C
(104°F) ambient temperature. Not more than three current-carrying conductors in raceway or cable or
earth (directly buried). For other conditions, dimension the cables according to local safety regulations,
appropriate input voltage and the load current of the drive.
Copper cables with concentric copper shield

Max. load current Cable type
A
AWG/kcmil
18 14
22 12
31 10
44 8
57 6
75 4
88 3
101 2
114 1
132 1/0
154 2/0
176 3/0
202 4/0
224 250 MCM or 2 x 1
251 300 MCM or 2 x 1/0
PDM code: 00096931
Technical data
104
Cable Entries
Brake resistor, input and motor cable (per phase) terminal sizes and tightening
torques are given below.
Frame U1, V1, W1, U2, V2, W2, R+, R- Earthing PE
size Maximum wire size Tightening torque Maximum wire size Tightening torque
AWG lbf ft AWG lbf ft
R2 up to 6 * 0.9…1.1 up to 8 1.1
R3 up to 6 * 0.9...1.1 up to 8 1.1
R4 up to 4 1.5…3.0 up to 5 2.2
R5 10...2/0 11.1 10...2/0 11.1
R6 3/0...350 MCM ** 14.8...29.5 4/0 5.9
* 6 AWG rigid solid cable, 8 AWG flexible stranded cable

** with cable lugs 6...2/0 AWG, tightening torque 14.8...29.5 lbf ft. Cable lugs are not included in the
delivery. See page 64.
Dimensions and weights

Frame size Height Width Depth* Weight
in. in. in. lb
R2 14.57 6.5 7.6...8.9 18
R3 16.54 6.81 9.11...10.43 29
R4 19.29 9.45 9.93...10.69 53
R5 23.70 10.43 10.85...11.11 71
R6 27.56 11.81 15.71 141
* Depth depends on the options included in the drive.
Input power connection

Voltage (U1) 208/220/230/240 VAC 3-phase ±10% for 230 VAC units
380/400/415 VAC 3-phase ±10% for 400 VAC units
380/400/415/440/460/480/500 VAC 3-phase ±10% for 500 VAC units
525/550/575/600/660/690 VAC 3-phase ±10% for 690 VAC units
Prospective short circuit Maximum allowed prospective short circuit current in the supply is 65 kA in a second
current (IEC 60439-1, providing that the mains cable of the drive is protected with appropriate fuses. US and
UL508 C) Canada: The drive is suitable for use on a circuit capable of delivering not more than
100 kA rms symmetrical amperes at the drive nominal voltage when protected by CC or 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)
Technical data
105
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
fFWP: frequency at field weakening point; UNmains: mains (input power) voltage;
UNmotor: rated motor voltage; fNmotor: rated motor frequency
Frequency resolution 0.01 Hz
Current See section IEC data.
Power limit 1.5 · Phd, 1.1 · PN or Pcont.max (whichever value is greatest)
Field weakening point 8 to 300 Hz
Switching frequency 3 kHz (average). In 690 V units 2 kHz (average).
Maximum recommended Sizing method Max. motor cable length
motor cable length DTC control Scalar control
according to I2N and I2hd R2 to R3: 100 m (328 ft) R2: 150 m (492 ft)
according to Icont.max at R4 to R6: 300 m (984 ft) R3 to R6: 300 m (984 ft)
ambient temperatures below
30°C (86°F)
according to Icont.max at R2: 50 m (164 ft) Note: This applies to units with EMC filter
ambient temperatures above also.
30°C (86°F) R3 and R4: 100 m (328 ft)
R5 and R6: 150 m (492 ft)
Note: With cables longer than 100 m (328 ft), the EMC Directive requirements may not be
fulfilled. See section CE marking.
Efficiency
Approximately 98% at nominal power level
Cooling
Method Internal fan, flow direction from bottom to top.
Free space around the unit See chapter Mechanical installation.
Degrees of protection
IP20 (UL open type). See chapter Planning the cabinet assembly.
Technical data
106
AGPS-11C
Nominal input voltage 115...230 VAC ±10%
Nominal input current 0.1 A (230 V) / 0.2 A (115 V)
Nominal frequency 50/60 Hz
Max. external fuse 16 A
X1 terminal sizes 3 x 2.5 mm2
Output voltage 15 VDC ±0.5 V
Nominal output current 0.4 A
X2 terminal block type JST B4P-VH
Ambient temperature 0...50°C
Relative humidity Max. 90%, no condensation allowed
Dimensions (with enclosure) 167 x 128 x 52 mm (Height x Width x Depth)
Weight (with enclosure) 0.75 kg
Approvals C-UL, US listed
Ambient conditions
Environmental limits for the drive are given below. The drive is to be used in a heated,
indoor, controlled environment.
Operation Storage Transportation
installed for stationary use in the protective package in the protective package
Installation site altitude 0 to 4000 m (13123 ft) above - -
sea level [above 1000 m
(3281 ft), see section
Derating]
Air temperature -15 to +50°C (5 to 122°F). No -40 to +70°C (-40 to +158°F) -40 to +70°C (-40 to +158°F)
frost allowed. See section
Derating.
Relative humidity 5 to 95% Max. 95% Max. 95%
No condensation allowed. Maximum allowed relative humidity is 60% in the presence of
corrosive gases.
Contamination levels No conductive dust allowed.
(IEC 60721-3-3, IEC 60721-3- Boards without coating: Boards without coating: Boards without coating:
2, IEC 60721-3-1) Chemical gases: Class 3C1 Chemical gases: Class 1C2 Chemical gases: Class 2C2
Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2
Boards with coating: Boards with coating: Boards with coating:
Chemical gases: Class 3C2 Chemical gases: Class 1C2 Chemical gases: Class 2C2
Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2
Atmospheric pressure 70 to 106 kPa 70 to 106 kPa 60 to 106 kPa
0.7 to 1.05 atmospheres 0.7 to 1.05 atmospheres 0.6 to 1.05 atmospheres
Vibration (IEC 60068-2)* Max. 1 mm (0.04 in.) Max. 1 mm (0.04 in.) Max. 3.5 mm (0.14 in.)
(5 to 13.2 Hz), (5 to 13.2 Hz), (2 to 9 Hz),
max. 7 m/s2 (23 ft/s2) max. 7 m/s2 (23 ft/s2) max. 15 m/s2 (49 ft/s2)
(13.2 to 100 Hz) sinusoidal (13.2 to 100 Hz) sinusoidal (9 to 200 Hz) sinusoidal
Shock (IEC 60068-2-29) Not allowed Max. 100 m/s2 (330 ft./s2), Max. 100 m/s2 (330 ft./s2),
11 ms 11 ms
Free fall Not allowed 250 mm (10 in.) for weight 250 mm (10 in.) for weight
under 100 kg (220 lb) under 100 kg (220 lb)
100 mm (4 in.) for weight 100 mm (4 in.) for weight
over 100 kg (220 lb) over 100 kg (220 lb)
2. For higher vibration use the
*Note: For frame sizes R2 to R4 with panel option maximum allowed vibration is 3 m/s
RPMP kit. See Control Panel Mounting Platform Kit (RPMP) Installation Guide [3AFE64677560 (English)].
Technical data
107
Materials
Drive enclosure • PC/ABS 2.5 mm, colour NCS 1502-Y (RAL 90021 / PMS 420 C)
• hot-dip zinc coated steel sheet 1.5 to 2 mm, thickness of coating 100 micrometres
• cast aluminium AlSi (R2 and R3)
• extruded aluminium AlSi (R4 to R6)
Package Corrugated cardboard (frames R2 to R5 and option modules), plywood and wood (frame
size R6), expanded polystyrene. Plastic covering of the package: 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.
Applicable standards
The drive complies with the following standards. The compliance with the European Low
Voltage Directive is verified according to standards EN 50178 and EN 60204-1.
• EN 50178 (1997) Electronic equipment for use in power installations
• EN 60204-1 (1997) Safety of machinery. Electrical equipment of machines. Part 1: General requirements.
Provisions for compliance: The final assembler of the machine is responsible for installing
- an emergency-stop device
- a supply disconnecting device
- the ACS800-04/U4 into a cabinet.
• EN 60529: 1991 Degrees of protection provided by enclosures (IP code)
(IEC 60529)
• IEC 60664-1 (1992) Insulation coordination for equipment within low-voltage systems. Part 1: Principles,
requirements and tests.
• EN 61800-3 (2004) Adjustable speed electrical power drive systems. Part 3: EMC requirements and specific
test methods
• UL 508C UL Standard for Safety, Power Conversion Equipment, second edition
• NEMA 250 (2003) Enclosures for Electrical Equipment (1000 Volts Maximum)
• CSA C22.2 No. 14-95 Industrial control equipment
Technical data
108
CE marking
A CE mark is attached to the drive to verify that the unit follows the provisions of the European Low
Voltage and EMC Directives (Directive 73/23/EEC, as amended by 93/68/EEC and Directive 89/336/
EEC, as amended by 93/68/EEC).
Definitions
EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to
operate without problems within an electromagnetic environment. Likewise, the equipment must not
disturb or interfere with any other product or system within its locality.
First environment includes establishments connected to a low-voltage network which supplies buildings
used for domestic purposes.
Second environment includes establishments connected to a network not supplying domestic premises.
Drive of category C2: drive of rated voltage less than 1000 V and intended to be installed and
commissioned only by a professional when used in the first environment. Note: A professional is
a person or organisation having necessary skills in installing and/or commissioning power drive
systems, including their EMC aspects.
Drive of category C3: drive of rated voltage less than 1000 V and intended for use in the second
environment and not intended for use in the first environment.
Drive of category C4: drive of rated voltage equal to or above 1000 V, or rated current equal to or above
400 A, or intended for use in complex systems in the second environment.
Compliance with the EMC Directive

The EMC Directive defines the requirements for immunity and emissions of electrical equipment used
within the European Union. The EMC product standard [EN 61800-3 (2004)] covers requirements
stated for drives.
Compliance with the EN 61800-3 (2004)

First environment (drive of category C2)
The drive complies with the standard with the following provisions:
1. The drive is equipped with EMC filter +E202.
2. The motor and control cables are selected as specified in the Hardware Manual.
3. The drive is installed according to the instructions given in the Hardware Manual.
4. Maximum cable length is 100 metres.
WARNING! The drive may cause radio interference if used in a residential or domestic environment.
The user is required to take measures to prevent interference, in addition to the requirements for CE
compliance listed above, if necessary.
Note: It is not allowed to install a drive equipped with EMC filter +E202 on IT (unearthed) systems. The
supply network becomes connected to earth potential through the EMC filter capacitors which may
cause danger or damage the unit.
Technical data
109
Second environment (drive of category C3)

1. Frame sizes R2…R5: The drive is equipped with EMC filter +E200. The filter is suitable for TN
(earthed) networks only.
Frame size R6: The drive is equipped with EMC filter +E210. The filter is suitable for TN (earthed)
and IT (unearthed) networks.
WARNING! A drive of category C3 is not intended to be used on a low-voltage public network which
supplies domestic premises. Radio frequency interference is expected if the drive is used on such
a network.
If the provisions under Second environment (drive of category C3) cannot be met, e.g. the drive cannot
be equipped with EMC filter +E200 when installed to an IT (unearthed) network, the requirements of the
standard can be met as follows:
1. It is ensured that no excessive emission is propagated to neighbouring low-voltage networks. In
some cases, the inherent suppression in transformers and cables is sufficient. If in doubt, a supply
transformer with static screening between the primary and secondary windings can be used.
Medium voltage network

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

Equipment
Drive
(victim)
Equipment Equipment
2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available
from the local ABB representative.
a network.
Machinery Directive
The drive complies with the European Union Machinery Directive (98/37/EC) requirements for an
equipment intended to be incorporated into machinery.
Technical data
110
“C-tick” marking
“C-tick” marking is required in Australia and New Zealand. A “C-tick” mark is attached to each drive in
order to verify compliance with the relevant standard (IEC 61800-3 (2004) – Adjustable speed electrical
power drive systems. Part 3: EMC requirements and specific test methods), mandated by the
Trans-Tasman Electromagnetic Compatibility Scheme.
Definitions
EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to
operate without problems within an electromagnetic environment. Likewise, the equipment must not
disturb or interfere with any other product or system within its locality.
The Trans-Tasman Electromagnetic Compatibility Scheme (EMCS) was introduced by the Australian
Communication Authority (ACA) and the Radio Spectrum Management Group (RSM) of the New
Zealand Ministry of Economic Development (NZMED) in November 2001. The aim of the scheme is to
protect the radiofrequency spectrum by introducing technical limits for emission from electrical/
electronic products.
First environment includes establishments connected to a low-voltage network which supplies buildings
used for domestic purposes.
Second environment includes establishments connected to a network not supplying domestic premises.
Drive of category C2: drive of rated voltage less than 1000 V and intended to be installed and
commissioned only by a professional when used in the first environment. Note: A professional is
a person or organisation having necessary skills in installing and/or commissioning power drive
systems, including their EMC aspects.
Drive of category C3: drive of rated voltage less than 1000 V and intended for use in the second
environment and not intended for use in the first environment.
Drive of category C4: drive of rated voltage equal to or above 1000 V, or rated current equal to or above
400 A, or intended for use in complex systems in the second environment.
Compliance with IEC 61800-3

First environment (drive of category C2)
The drive complies with the limits of IEC 61800-3 with the following provisions:
1. The drive is equipped with EMC filter +E202.
3. The motor and control cables used are selected as specified in the Hardware Manual.
Note: The drive must not be equipped with EMC filter +E202 when installed to IT (unearthed) systems.
The mains becomes connected to earth potential through the EMC filter capacitors. In IT systems this
may cause danger or damage the unit.
Technical data
111

1. Frame sizes R2…R5: The drive is equipped with EMC filter +E200. The filter is suitable for TN
(earthed) networks only.
Frame size R6: The drive is equipped with EMC filter +E210. The filter is suitable for TN (earthed)
and IT (unearthed) networks.
a network.
If the provisions under Second environment (drive of category C3) cannot be met, e.g. the drive cannot
be equipped with EMC filter +E200 when installed to an IT (unearthed) network, the requirements of the
standard can be met as follows for restricted distribution:
1. It is ensured that no excessive emission is propagated to neighbouring low-voltage networks. In
some cases, the inherent suppression in transformers and cables is sufficient. If in doubt, a supply
transformer with static screening between the primary and secondary windings can be used.
Medium voltage network

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

Equipment
Drive
(victim)
Equipment Equipment
2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available
from the local ABB representative.
a network.
Marine type approvals

ACS800-04+C132 and ACS800-U4+C132 are type approved by American Bureau of Shipping, Bureau
Veritas, Germanischer Lloyd, Lloyd’s Register of Shipping, Det Norske Veritas and RINA.
Marine type approvals are pending for the following types:
ACS800-xx-0135-3+C132, ACS800-xx-0165-3+C132, ACS800-xx-0165-5+C132, ACS800-xx-0205-
5+C132, ACS800-xx-0145-7+C132, ACS800-xx-0175-7+C132 and ACS800-xx-0205-7+C132.
Technical data
112
UL/CSA markings
The ACS800-04 and ACS800-U4 are C-UL US listed and CSA marked.
UL
The drive is suitable for use on a circuit capable of delivering not more than 65 kA rms symmetrical
amperes at the drive nominal voltage (600 V maximum for 690 V units).
The drive provides overload protection in accordance with the National Electrical Code (US). See
ACS800 Firmware Manual for setting. Default setting is off, must be activated at start-up.
The drives are to be used in a heated indoor controlled environment. See section Ambient conditions
for specific limits.
Brake chopper - ABB has brake choppers that, when applied with appropriately sized brake resistors,
will allow the drive to dissipate regenerative energy (normally associated with quickly decelerating
a motor). Proper application of the brake chopper is defined in chapter Resistor braking. This can be
applied to a single drive or multiple drives with DC bus connected to allow a sharing of regenerative
energy.
Equipment warranty and liability

The manufacturer warrants the equipment supplied against defects in design, materials and
workmanship for a period of twelve (12) months after installation or twenty-four (24) months from date
of manufacturing, whichever first occurs. The local ABB office or distributor may grant a warranty period
different to the above and refer to local terms of liability as defined in the supply contract.
The manufacturer is not responsible for
• any costs resulting from a failure if the installation, commissioning, repair, alternation, or ambient
conditions of the drive do not fulfil the requirements specified in the documentation delivered with
the unit and other relevant documentation.
• units subjected to misuse, negligence or accident
• units comprised of materials provided or designs stipulated by the purchaser.
In no event shall the manufacturer, its suppliers or subcontractors be liable for special, indirect,
incidental or consequential damages, losses or penalties.
This is the sole and exclusive warranty given by the manufacturer with respect to the equipment and is
in lieu of and excludes all other warranties, express or implied, arising by operation of law or otherwise,
including, but not limited to, any implied warranties of merchantability or fitness for a particular purpose.
If you have any questions concerning your ABB drive, please contact the local distributor or ABB office.
The technical data, information and specifications are valid at the time of printing. The manufacturer
reserves the right to modifications without prior notice.
Technical data
113
Product protection in the US

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
5,612,604 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 7,057,908 7,059,390 7,067,997
7,082,374 7,084,604 7,098,623 7,102,325 D503,931 D510,319
D510,320 D511,137 D511,150 D512,026 D512,696 D521,466.
Other patents are pending.
Technical data
114
Technical data
115

Dimensional drawings of the ACS800-04/U4, flange mounting kits and AGPS board
are shown below. The dimensions are given in millimetres and [inches].
116
Frame size R2 (with optional control panel)
3AFE68347432
117
3AFE68360544
118
3AFE68364655
119
3AFE68365741
120
3AFE68365945
121
Flange mounting kits

Flange mounting kit dimensions:
Lifting lug
7 [0.276]
H
D
Frame size H W D
mm [in.] mm [in.] mm [in.]
R2 476.5 [18.76] 235.5 [9.27] 25 [0.984]
R3 530.5 [20.89] 245.5 [9.67] 25 [0.984]
R4 595.95 [23.46] 373.6 [14.71] 25 [0.984]
R5 700 [27.56] 398.8 [15.70] 25 [0.984]
R6 786 [30.94] 433.4 [17.06] 25 [0.984]
122
Flange mounting kit for frame size R2
[5.51]
[0.276]
[15.16]
22
[0.866] [7.54]
[5.51]
[2.17]
98.25
[3.87]
[0
.7
87
]
3AFE68361001
[6.69]
123
[7.09]
[0.394]
[6.30]
[17.32]
[0.276]
[6.30]
22
105.25
[2.36]
[4.14]
[0.866] [7.93]
3AFE68370418
124
86.8
[3.42]
142.95
[5.63]
[12.40]
21
[4.96]
[0.827]
[0.276]
[11.81]
[20.08]
[6.53]
[1.30]
[5.23]
[3.94]
[6.02]
]
153
87
3AFE68375371
.7
[0
125
[4.33] [13.39]
[14.33]
[8.66]
[0.276]
[24.57]
[8.66]
[0.866]
[4.33]
[3.15]
[5.12]
130
3AFE68371619
]
87
.7
119.4
[0
[4.70]
126
[8.66]
[0
.7
87
]
[0.709]
18
[4.84]
16.7
[15.75] [0.657]
[6.61]
[0.276]
[6.61]
[28.35]
[6.61]
[3.94]
[0.787]
[4.84]
3AFE68367280
]
100
87
116.7
.7
[4.59] [3.94]
[0
127
AGPS board
3AFE68293898
128
129
Resistor braking

This chapter describes how to select, protect and wire brake choppers and resistors.
The chapter also contains the technical data.
Availability of brake choppers and resistors

Frame R2 and R3 drives and 690 V units of frame size R4 have a built-in brake
chopper as standard equipment. For other units, brake choppers are optionally
available as built-in units, indicated in the type code by +D150.
Resistors are available as add-on kits.
How to select the correct drive/chopper/resistor combination

1. Calculate the maximum power (Pmax) generated by the motor during braking.
2. Select a suitable drive / brake chopper / brake resistor combination for the
application according to the following tables (take account of other factors in the
drive selection also). The following condition must be met:
Pbrcont > Pmax
3. Check the resistor selection. The energy generated by the motor during a 400
second period must not exceed the resistor heat dissipation capacity ER.
If the ER value is not sufficient, it is possible to use a four-resistor assembly in which two standard
resistors are connected in parallel, two in series. The ER value of the four-resistor assembly is four
times the value specified for the standard resistor.
Resistor braking
130
Note: A resistor other than the standard resistor can be used provided that:
• its resistance is not lower than the resistance of the standard resistor.
• the resistance does not restrict the braking capacity needed, i.e.
2
UDC
Pmax <
R
where
Pmax maximum power generated by the motor during braking
UDC voltage over the resistor during braking, e.g.
1.35 · 1.2 · 415 VDC (when supply voltage is 380 to 415 VAC),
1.35 · 1.2 · 500 VDC. (when supply voltage is 440 to 500 VAC) or
1.35 · 1.2 · 690 VDC (when supply voltage is 525 to 690 VAC).
R resistor resistance (ohm)
• the heat dissipation capacity (ER) is sufficient for the application (see step 3
above).
WARNING! Never use a brake resistor with a resistance below the value specified
for the particular drive / brake chopper / resistor combination. The drive and the
chopper are not able to handle the overcurrent caused by the low resistance.
Optional brake chopper and resistor(s)

The nominal ratings for dimensioning the brake resistors are given below at an
ambient temperature of 40°C (104°F).
ACS800-04 type Braking power of the chopper and Brake resistor(s)
ACS800-U4 type the drive
Pbrcont Type R ER PRcont
(kW) (ohm) (kJ) (kW)
230 V units
-0001-2 0.55 SACE08RE44 44 210 1
-0002-2 0.8 SACE08RE44 44 210 1
-0003-2 1.1 SACE08RE44 44 210 1
-0004-2 1.5 SACE08RE44 44 210 1
-0005-2 2.2 SACE15RE22 22 420 2
-0006-2 3.0 SACE15RE22 22 420 2
-0009-2 4.0 SACE15RE22 22 420 2
-0011-2 5.5 SACE15RE13 13 435 2
-0016-2 11 SAFUR90F575 8 1800 4.5
-0020-2 17 SAFUR90F575 8 1800 4.5
-0025-2 23 SAFUR80F500 6 2400 6
-0030-2 28 SAFUR125F500 4 3600 9
-0040-2 33 SAFUR125F500 4 3600 9
-0050-2 45 2xSAFUR125F500 2 7200 18
-0060-2 56 2xSAFUR125F500 2 7200 18
-0070-2 68 2xSAFUR125F500 2 7200 18
Resistor braking
131

400 V units
-0003-3 1.1 SACE08RE44 44 210 1
-0004-3 1.5 SACE08RE44 44 210 1
-0005-3 2.2 SACE08RE44 44 210 1
-0006-3 3.0 SACE08RE44 44 210 1
-0009-3 4.0 SACE08RE44 44 210 1
-0011-3 5.5 SACE15RE22 22 420 2
-0016-3 7.5 SACE15RE22 22 420 2
-0020-3 11 SACE15RE22 22 420 2
-0023-3 11 SACE15RE22 22 420 2
-0025-3 23 SACE15RE13 13 435 2
-0030-3 28 SACE15RE13 13 435 2
-0035-3 28 SACE15RE13 13 435 2
-0040-3 33 SAFUR90F575 8 1800 4.5
-0050-3 45 SAFUR90F575 8 1800 4.5
-0060-3 56 SAFUR90F575 8 1800 4.5
-0070-3 68 SAFUR80F500 6 2400 6
-0100-3 83 SAFUR125F500 4 3600 9
-0120-3 113 SAFUR125F500 4 3600 9
-0135-3 132 SAFUR200F500 2.7 5400 13.5
-0165-3 132 SAFUR200F500 2.7 5400 13.5
500 V units
-0004-5 1.5 SACE08RE44 44 210 1
-0005-5 2.2 SACE08RE44 44 210 1
-0006-5 3.0 SACE08RE44 44 210 1
-0009-5 4.0 SACE08RE44 44 210 1
-0011-5 5.5 SACE08RE44 44 210 1
-0016-5 7.5 SACE15RE22 22 420 2
-0020-5 11 SACE15RE22 22 420 2
-0025-5 15 SACE15RE22 22 420 2
-0028-5 15 SACE15RE22 22 420 2
-0030-5 28 SACE15RE13 13 435 2
-0040-5 33 SACE15RE13 13 435 2
-0045-5 33 SACE15RE13 13 435 2
-0050-5 45 SAFUR90F575 8 1800 4.5
-0060-5 56 SAFUR90F575 8 1800 4.5
-0070-5 68 SAFUR90F575 8 1800 4.5
-0100-5 83 SAFUR125F500 4 3600 9
-0120-5 113 SAFUR125F500 4 3600 9
-0140-5 135 SAFUR125F500 4 3600 9
-0165-5 160 SAFUR125F500 4 3600 9
-0205-5 160 SAFUR125F500 4 3600 9
Resistor braking
132

690 V units
-0011-7 8.0 SACE08RE44 44 210 1
-0016-7 11 SACE08RE44 44 210 1
-0020-7 16 SACE08RE44 44 210 1
-0025-7 20 SACE08RE44 44 210 1
-0030-7 28 SACE15RE22 22 420 2
-0040-7 22 / 33 (1 SACE15RE22 22 420 2
-0050-7 45 SACE15RE13 13 435 2
-0060-7 56 SACE15RE13 13 435 2
-0070-7 68 SAFUR90F575 8 1800 4.5
-0100-7 83 SAFUR90F575 8 1800 4.5
-0120-7 113 SAFUR80F500 6 2400 6
-0145-7 160 SAFUR80F500 6 2400 6
-0175-7 160 SAFUR80F500 6 2400 6
-0205-7 160 SAFUR80F500 6 2400 6
PDM code 00096931-J
PbrcontThe drive and the chopper will withstand this continuous braking power. The braking is considered continuous if the
braking time exceeds 30 s.
Note: The braking energy transmitted to the specified resistor(s) in 400 seconds may not exceed ER.
R Resistance value for the listed resistor assembly. Note: This is also the minimum allowed resistance for the braking
resistor.
ER Short energy pulse that the resistor assembly withstands every 400 seconds. This energy will heat the resistor
element from 40°C (104°F) to the maximum allowable temperature.
PRcont Continuous power (heat) dissipation of the resistor when placed correctly. Energy ER dissipates in 400 seconds.
1)
22 kW with standard 22 ohm resistor and 33 kW with 32…37 ohm resistor
All braking resistors must be installed outside the converter module. The SACE braking resistors are built in an IP21 metal
housing. The SAFUR braking resistors are built in an IP00 metal frame. Note: The SACE and SAFUR resistors are not UL
listed.
Resistor installation and wiring

All resistors must be installed outside the drive module in a place where they will
cool.
WARNING! The materials near the brake resistor must be non-flammable. The
surface temperature of the resistor is high. Air flowing from the resistor is of
hundreds of degrees Celsius. Protect the resistor against contact.
Use the cable type used for drive input cabling (see to chapter Technical data) to
ensure the input fuses will also protect the resistor cable. Alternatively, two-
conductor shielded cable with the same cross-sectional area can be used. The
maximum length of the resistor cable(s) is 10 m (33 ft). For the connections, see the
power connection diagram of the drive.
Resistor braking
133
Protection of frame sizes R2 to R5

It is highly recommended to equip the drive with a main contactor for safety reasons.
Wire the contactor so that it opens in case the resistor overheats. This is essential
for safety since the drive will not otherwise be able to interrupt the main supply if the
chopper remains conductive in a fault situation.
Below is a simple example wiring diagram.
L1 L2 L3
1
OFF
Fuses 2
1 3 5 13 3
ON
2 4 6 14 4
ACS800
U1 V1 W1
Θ Thermal switch (stand-
ard in ABB resistors)
K1
Resistor braking
134
Protection of frame size R6

A main contactor is not required for protecting against resistor overheating when the
resistor is dimensioned according to the instructions and the internal brake chopper
is used. The drive will disable power flow through the input bridge if the chopper
remains conductive in a fault situation. Note: If an external brake chopper (outside
the drive module) is used, a main contactor is always required.
A thermal switch (standard in ABB resistors) is required for safety reasons. The
cable must be shielded and not longer than the resistor cable.
With Standard Application Program, wire the thermal switch as shown below. By
default, the drive will stop by coasting when the switch opens.
RMIO:X22 or X2: X22
1 DI1
2 DI2
3 DI3
4 DI4
5 DI5
6 DI6
7 +24V
Resistor thermal
8 +24V
switch (standard in
ABB resistors) 9 DGND
Θ
10 DGND
11 DIIL
For other application programs, the thermal switch may be wired to a different digital
input. Programming of the input to trip the drive by “EXTERNAL FAULT” may be
needed. See the appropriate Firmware Manual.
Brake circuit commissioning

For Standard Application Program:
• Enable the brake chopper function (parameter 27.01).
• Switch off the overvoltage control of the drive (parameter 20.05).
• Check the resistance value setting (parameter 27.03).
• Frame sizes R6: Check the setting of parameter 21.09. If stop by coasting is
required, select OFF2 STOP.
For the use of the brake resistor overload protection (parameters 27.02...27.05),
consult an ABB representative.
WARNING! If the drive is equipped with a brake chopper but the chopper is not
enabled by parameter setting, the brake resistor must be disconnected because the
protection against resistor overheating is then not in use.
For settings of other application programs, see the appropriate Firmware Manual.
Resistor braking
3AFE68372984 Rev C EN
EFFECTIVE: 16.2.2007
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 22 211 USA Fax +86 10 5821 7618
Telefax +358 10 22 22681 Telephone 262 785-3200 Internet www.abb.com
Internet www.abb.com 800-HELP-365
Fax 262 780-5135

ACS800 04 Technical Manual 0 55kW To 160kW

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ACS800

HARDWARE MANUALS (appropriate manual is included in the

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

FIRMWARE MANUALS, SUPPLEMENTS AND GUIDES

Standard Application Program Firmware Manual

OPTION MANUALS (delivered with optional equipment)

Fieldbus Adapters, I/O Extension Modules etc.

© 2007 ABB Oy. All Rights Reserved.

What this chapter contains

Use of warnings and notes

Dangerous voltage warning warns of high voltage which can cause

General warning warns about conditions, other than those caused by

Installation and maintenance work

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

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

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

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

• In first environment (EU EMC Directive): make a 360° high frequency

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

Mechanical installation and maintenance

• Handle the unit carefully.

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

• Ensure sufficient cooling.

• Do not fasten the drive by riveting or welding.

Printed circuit boards

• The printed circuit boards contain components sensitive to electrostatic

Fibre optic cables

WARNING! Ignoring the following instructions can cause equipment malfunction

• Do not activate automatic fault reset functions of the Application Program if

Permanent magnet motor

Installation and maintenance work

Start-up and operation

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

About this manual

Planning the cabinet assembly

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Planning the electrical installation

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

Motor control and I/O board (RMIO)

Frame size R5 (with optional control panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

About this manual

What this chapter contains

Categorization according to the frame size

Categorization according to the + code

About this manual

About this manual

Installation and commissioning flowchart

Plan the installation. Technical data

Check the installation site. Mechanical installation: Before installation

If the drive is about to be connected to an IT ACS800-04/U4: Type code

Install the drive in a cabinet. Mechanical installation

Route the cables. Planning the electrical installation: Routing the

About this manual

Check the installation. Installation checklist

Commission the drive. Appropriate Firmware Manual

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

Product and service inquiries

Providing feedback on ABB Drives manuals

About this manual