En Acs800 107 HW C

ACS800
Hardware Manual
ACS800-107 Cabinet-built Inverter Units (1.5 to 5430 kW)
ACS800-107 Cabinet-built Inverter Units
1.5 to 5340 kW
Hardware Manual
3AFE68233453 REV C
EN
EFFECTIVE: 19.09.2005
© 2005 ABB Oy. All Rights Reserved.

5
Table of contents
Table of contents
Introduction to this manual

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Categorization according to the frame size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Related publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hardware description
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Typical drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inverter unit hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cabinet system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Inverter module frames R2i to R5i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Module layout (Frame size R3i pictured) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Inverter module frame R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Module layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Motor cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Frame R8i and multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Redundancy (Reduced run capability) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Control electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cabinet layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Motor cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
The RDCU Drive Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
The RAPI-01C Auxiliary Power Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
The CDP-312R Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Basic code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Option codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Table of contents
6
Electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Power connections – Frame R2i to R5i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Conductor stripping lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Frame R2i to R4i power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Frame R5i power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Power connections – Frame R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Power connections – Frame R8i and multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Motor connection – Units without common motor terminal cubicle . . . . . . . . . . . . . . . . . . . . .31
Connection diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Motor connection – Units with common motor terminal cubicle . . . . . . . . . . . . . . . . . . . . . . .36
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Connecting the control cables – Frame R2i to R5i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Frame R2i to R4i (R3i pictured) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Frame R5i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
External +24 V power supply for the RMIO board . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Connecting the control cables – Frame R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Connecting the control cables – Frame R8i and multiples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
360 degrees grounding of I/O cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
When the outer surface of the shield is covered with non-conductive material . . . . . . .44
Connecting the shield wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Wiring the Prevention of unexpected start circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Cabling of I/O and fieldbus modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Pulse encoder module cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Installation of optional modules and PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Fibre optic links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Motor control and I/O board (RMIO)

To which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Note on cabinet-built ACS800 drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Note on external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
External control connections (non-US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
External control connections (US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
RMIO board specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Analogue inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Constant voltage output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Auxiliary power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Analogue outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Table of contents
7
Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
DDCS fibre optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
24 VDC power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
External +24 V power supply for the RMIO board

When to use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Connecting +24 V external power supply – Frame R2i to R5i . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Installation checklist
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Commissioning
Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Checks with no voltage connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Connecting voltage to auxiliary circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Checks with auxiliary voltage connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Connecting voltage to inverter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Checks with voltage connected to inverter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Control from an overriding system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Disconnecting/Reconnecting an inverter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Maintenance
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Redundancy (Reduced run capability) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Checking and replacing the air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Heatsinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Fan replacement (R2i, R3i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Fan replacement (R4i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Additional fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Replacement (R2i, R3i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Replacement (R4i, R5i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
IP54 (UL type 12) fan replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Power connections (R8i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Capacitor reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Table of contents
8
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Technical data
Ratings, inverter modules used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
DC capacitance, DC fuses, noise, cooling characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Input power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Circuit diagrams
R2i/R3i inverter modules – Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
R4i inverter module – Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
R5i inverter module – Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
R7i inverter module – Internal diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
R8i inverter module – Internal diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
R8i inverter module – Charging circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
2×R8i inverter unit – Charging circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
3×R8i inverter unit – Charging circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
R8i inverter unit – I/O and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
2×R8i inverter unit – I/O and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Example – Emergency stop (Category 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Example – Prevention of unexpected start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Dimensions
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
General cabinet dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Free space requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Common motor terminal cubicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Table of contents
9
What this chapter contains

This chapter gives basic information on the manual.
Compatibility
The manual is compatible with ACS800 multidrive inverter units that form a part of an
ACS800 multidrive system. ACS800 multidrive inverter units have the basic type
designation of ACS800-107.
Safety instructions
Follow all safety instructions delivered with the drive.
• Read the complete safety instructions before you install, commission, or use
the drive. The complete safety instructions are given in the document ACS800
Multidrive: Safety Instructions (3AFE64760432 [English]).
• Read task specific safety instructions before starting the task. See the section
describing the task.
Reader
The reader of the manual is expected to know the standard electrical wiring
practices, electronic components, and electrical schematic symbols.
Contents
• Hardware description
• Electrical installation
• Motor control and I/O board (RMIO)
• External +24 V power supply for the RMIO board
• Installation checklist
• Commissioning
• Maintenance
• Technical data
• Circuit diagrams
• Dimensions.

10
Categorization according to the frame size

Some descriptions, instructions, technical data and dimensional drawings which
concern only a certain group of units may be marked with the symbol of the frame
size (such as “R2i”, “4×R8i”, etc.). The marking derives from the basic construction
of the inverter modules that form the inverter unit.
The frame size is not marked on the type designation labels. To identify the frame
size of an inverter unit, see the rating tables in chapter Technical data.
Related publications
• ACS800 Multidrive; Safety Instructions (3AFE64760432 [English])
• ACS800 Cabinet-built Multidrive; Mechanical Installation (3AFE68233402
[English])
• ACS800 Multidrive: Planning the Electrical Installation (3AFE64783742 [English])
• Appropriate supply unit manual
• Appropriate Firmware Manual.
Inquiries
Address any inquiries about the product to the local ABB representative, quoting the
type code and serial number of the unit in question. If the local ABB representative
cannot be contacted, address inquiries to ABB Oy, AC Drives, PO Box 184, 00381
Helsinki, Finland.

11
Terms and abbreviations

Term/ Explanation
Abbreviation
CMF Common mode filtering.
DDCS Distributed Drives Communication System; a protocol used in optical fibre

communication inside and between ABB drives.
Drive unit See Inverter unit.
DSU Diode supply unit (consisting of one or more diode supply modules).
DTC Direct Torque Control.
EMC Electromagnetic Compatibility.
Frame (size) Relates to the construction type of the component in question. For example,
several supply modules with different nominal powers may have the same basic
construction. The term is often used in reference to a group of components that
share a similar mechanical construction.
To determine the frame size of a component, 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.
Inverter unit An entity containing all inverter modules controlling a motor, together with their
control electronics, and I/O and auxiliary components.
I/O Input/Output.
NDBU or Types of optical branching unit for fibre links that use the DDCS protocol.
ADBU
NGPS or Gate driver Power Supply board. An optional board within inverter modules used to
AGPS implement the Prevention of unexpected start function.
NPBU or Types of optical branching unit used for connecting parallel-connected inverter
APBU modules to the RDCU.
PLC Programmable Logic Controller.
PPCS Power Plate Communication System; a protocol used in the optical fibre link that
controls the output semiconductors of an inverter module.
RDCU Drive control unit. The RDCU is a separate unit consisting of an RMIO board built
in a plastic housing. Module sizes R2i to R5i have the RMIO board built-in.
RFI Radio-Frequency Interference.
RMIO Motor control and I/O board. Contains the principal inputs and outputs of the drive.
Module sizes R2i to R5i have the RMIO board built-in; with larger units, the RMIO
is contained within a separate RDCU drive control unit.
THD Total Harmonic Distortion

12

13

This chapter describes a typical drive system and the hardware of the inverter unit.
The information is valid for all ACS800-107 inverter units.
Typical drive system

The diagram below depicts a common DC bus drive system.
M
2 5 5 6
M M M
M M
3~ 3~
1
1 – Input (AC) fuses
2 – Supply unit (in this example, consisting of two supply modules)
3 – DC bus
4 – Inverter DC fuses or switch fuses
5 – Inverter units (in this example, one of the units consists of two
inverter modules connected in parallel)
6 – Brake chopper(s) (optional)
14
Inverter unit hardware
General
An inverter unit contains the components required to control one motor. These
include one or more inverter modules connected in parallel, together with the
necessary auxiliary equipment such as control electronics, fusing, cabling and
switchgear.
ACS800-107 inverter units range from 1.5 to 5340 kW in power. ACS800-107
inverter units employ inverter modules from frame size R2i to R8i. Up to
approximately 500 kW, inverter units consist of one module only; higher powers are
achieved by connecting multiple R8i modules in parallel.
All inverter modules used in the ACS800-107 units have coated circuit boards as
standard.
Cabinet system
The inverter units are built in adjoining cubicles. Examples of the cabinet
configurations are included below as well as in the chapter Dimensions. The motor
cabling direction is optionally up or down – see below under each module frame size
for specific information.
The section Control interfaces below shows the available control and I/O options of
the inverter unit.
Cooling
Each inverter module has its own cooling fan(s). Control cubicles may have
additional cooling fans.
The inverter cubicles have the air intake at the lower part of the door, while the air
outlets are on the roof. The intake can optionally be through the floor, adding
130 mm (5.12”) to the standard depth of 600 mm (23.62”) of the cabinet.
15
Inverter module frames R2i to R5i

The motor (output) cables are connected to screw terminal blocks at the bottom of
the module, covered by a metal housing. The modules have a built-in RMIO (Motor
control and I/O) board, which contains the basic I/Os and slots for optional I/O
modules. For descriptions of the I/O terminals, see the chapter Motor control and I/O
board (RMIO).
R2i to R5i modules optionally contain an AGPS board for implementation of the
Prevention of unexpected start feature.
The cubicle is equipped with lead-throughs for the motor cables either at the bottom
or the top.
Module layout (Frame size R3i pictured)
Item Explanation
1 1 Control panel mounting platform and CDP

312R control panel (optional). Can be
turned aside.
2 DC (input) connections
4
3 Motor (output) connection
4 Slots for optional I/O modules

4
5 I/O terminal blocks on RMIO (obscured)
4
2 3
16
Cabinet layout
Several inverter modules of frame size R2i to R5i may be installed in one cubicle.
Each module is equipped with dedicated DC fuses or switch fuse. The modules have
an internal capacitor bank charging circuit.
The modules are mounted in a slightly inclined position. The picture below presents
an example of a cubicle with one R3i and one R5i module.
DC switch fuses for

each inverter unit
Frame R2i inverter

module
DC input cable
Frame R5i inverter

module
DC input cable
Control and I/O cable

lead-through
17
Inverter module frame R7i

The inverter cubicle is equipped with lead-throughs for the motor cables either at the
bottom or the top. As standard, the output busbars at the bottom of the inverter
module are extended to the front part of the cubicle for easy access.
The cooling fan is supplied from the auxiliary voltage circuit of the drive system, and
can be easily replaced by removing two screws and disconnecting a wire plug.
A control unit (RDCU-02C), containing the RMIO board with basic I/Os and slots for
optional I/O modules, is fitted on a rail beside the inverter module. For descriptions
of the I/O terminals, see the chapter Motor control and I/O board (RMIO).
Frame R7i modules are equipped with common mode filters as standard. Output
(du/dt) filters and Prevention of unexpected start are optionally available.
Module layout
Front view, with cooling

fan removed
1
1
Item Explanation
1 DC (input) connections.
6 2 Cooling fan.
6 3 Output busbars. By default,
these busbars are extended
to the front part of the cubicle.
4 Power connection for cooling

fan.
5 Fibre optic connectors.

5
5 6 Prevention of unexpected
start connector.
4
3
Motor cabling
The motor cables are connected to the output busbars at the bottom of the cubicle.
For top exit, the depth of the cabinet is increased by 130 mm.
18
Frame R8i and multiples

Inverter units for high powers are constructed from one or more frame R8i inverter
modules. The modules run on wheels, which, along with the quick connector at the
motor output, enable quick replacement of a module for maintenance.
1
3
5
2
Item Explanation
1 DC (input) connections
2 Output busbars. Match the quick connector socket mounted in the cubicle
3 Fibre optic connectors of the AINT board. Connected to the RDCU drive control unit (via
an NPBU branching unit in case of parallel inverter modules)
4 Retractable support legs
5 Handle
6 Cooling fan
19
Redundancy (Reduced run capability)

If one of several parallel-connected modules has to be removed from the cabinet for
service, the remaining modules can continue to be run at reduced power. See page
68 for information on utilising this feature.
Cooling fan
The cooling fan at the base of the inverter module is usually fed from the auxiliary
voltage supply of the cabinet. A speed-controlled fan is optionally available, involving
an additional power supply board and a fan inverter board that outputs a frequency
in the range of 5 to 55 Hz to the fan. The fan is regulated according to the
temperature of the output stage of the module. Through drive parameters, other
operating modes, such as constant speed, may also be available; see the
appropriate Firmware Manual delivered with the drive.
Control electronics
R8i modules employ a separate control unit (RDCU-02C) that contains the RMIO
board with basic I/Os and slots for optional I/O modules. For descriptions of the I/O
terminals, see the chapter Motor control and I/O board (RMIO). A fibre optic link
connects the RDCU control unit to the AINT board of the inverter module. If the
inverter unit consists of multiple R8i modules, the control signal is distributed to all
the modules through an APBU or NPBU branching unit.
The control electronics are typically located in a 300 mm wide control cubicle. One
cubicle holds the electronics of two inverter units. As standard, the drive control units
are mounted on the back wall of the cubicle, while the branching units are mounted
on the right-hand wall.
20
Cabinet layout
Several inverter modules may be installed in one cubicle. Each module is equipped
with dedicated DC fuses; a switch fuse is optional. When modules equipped with a
switch fuse are powered, a charging circuit automatically charges the capacitor
banks of the modules before the main contacts of the switch fuse close.
The picture below presents an example of a cubicle with two R8i inverter modules.
DC fuses for each

inverter module
Inverter modules
Fibre optic link from

control unit (through
branching unit)
Motor cabling
The motor cable is connected to the module via a quick connector at the back of the
module. With a common motor terminal cubicle (optional), the outputs of the parallel-
connected inverter modules are run to separate cubicle containing a single set of
output busbars. The cubicle is available in bottom-exit and top-exit variants.
If a common motor terminal cubicle (optional) is not present, each inverter module
must be extracted from the cabinet for motor cabling and then re-inserted. In this
case, each inverter module is to be cabled individually to the motor. The standard
cabling direction is down; top exit adds 130 mm to the depth of the cubicle.
21
Control interfaces
The following diagram shows the control interfaces and I/O options of an inverter
unit.
The RDCU Drive Control Unit

The inverter unit is controlled by an RDCU drive control unit which incorporates the
RMIO board. The RDCU is connected to the inverter module(s) by a fibre optic link,
distributed through an APBU optical branching unit if necessary. In the inverter
module, the optic link connects to the AINT/NINT board.
The RAPI-01C Auxiliary Power Interface Board
The RDCU is optionally equipped with an auxiliary power interface board (RAPI).
The RAPI board ensures the “POWER FAIL” function of the RMIO board can be
carried out in case the 24 V auxiliary power to the RDCU is interrupted, i.e. the fault
and alarm loggers have enough time to write collected data into the flash memory.
The CDP-312R Control Panel

The CDP-312R is the user interface of the inverter unit, providing the essential
controls such as Start/Stop/Direction/Reset/Reference, and the parameter settings
for the application program. See the appropriate Firmware Manual for further
information.
The front cover of frame R5i has a platform for the CDP 312R control panel; frame
sizes R2i to R4i require an additional platform kit if the panel needs to be mounted
on the module. With other frame sizes, the panel can be installed on a separate
mounting platform e.g. on the door.
22
*Drive control unit

(RDCU)
CDP 312R Control Panel Optional module 1: I/O extension (RAIO,

*Motor control
and related accessories RDIO), pulse encoder interface (RTAC), or
and I/O board
(RMIO) fieldbus adapter (e.g. RMBA, RDNA, RPBA)
Optional module 2: I/O extension (RAIO,

External control via RDIO) or pulse encoder interface (RTAC)
analogue/digital inputs Optional module 3: DDCS communication
and outputs option (RDCO-0x)
*In frame sizes R2i to
The fibre optic channels provided by the
R5i, the RMIO board is
RDCO module can be used for I/O extension
built in the inverter
(using NAIO/NDIO modules), pulse encoder
module instead of a
connection (NTAC module), fieldbus
separate RDCU unit.
connection (Nxxx fieldbus adapter modules),
PC connection (DriveWare® PC tools), or
master/follower connection.
= ~
~
Input power
= To motor
Supply unit Inverter unit
Brake choppers and

resistors (optional)
23
Type code
Each inverter unit has a type designation label. (Note that multiple small inverter
units can be installed within one cubicle.) The type code on the label contains
information on the specifications and configuration of the unit.
• The first 17 digits form the basic code. It describes the basic construction of the
unit. The fields in the basic code are separated with hyphens.
• The option codes follow the basic code. Each option code starts with an
identifying letter (common for the whole product series), followed by descriptive
digits. The option codes are separated by plus signs.
The main selections are described below. Not all options are necessarily available
for all types. For more information, contact your local ABB representative.
Basic code
Digit no. Name/Description Alternatives Description
1…6 Product series ACS800
8…10 Construction 107 Inverter unit
12…14 Size 0003 and up 3 kVA and up
16 Voltage rating 3 380/400/415 V. Nominal voltage: 400 V.
5 380/400/415/440/460/480/500 V. Nominal
voltage: 500 V.
7 525/575/600/660/690 V. Nominal voltage: 690 V.
Option codes
Identification Name/Description Alternatives Description
B Degree of protection – IP21 (UL type 1)
B053 IP22 (UL type 1)
H Cabling options H352 Bottom exit
H353 Top exit
Q Safety options Q950 Prevention of unexpected start
Q953 Earth fault monitoring (for earthed supply

network)
24
25

This chapter describes the electrical installation procedure of the ACS800-107
inverter units with ACS800-104 inverter modules.
The tightening torques for the electrical connections are listed in the chapter
Technical data.
WARNING! Make sure that the drive system is disconnected from the mains (input
power) during installation. If the drive system is already connected to the mains, wait
for 5 min after disconnecting mains power.
Checking the insulation of the assembly

Every ACS800-107 inverter unit and ACS800-104 inverter module has been tested
for insulation between the main circuit and the chassis (2500 V rms 50 Hz for 1
second) at the factory. Therefore, do not make any voltage tolerance or insulation
resistance tests (e.g. hi-pot or megger) on the inverter units or modules. Check the
insulation of the assembly as follows.
WARNING! Check the insulation before connecting the drive to the main supply.
Make sure that the drive is disconnected from the mains (input power).
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.
26
Power connections – Frame R2i to R5i
Diagram
Inverter module
OUTPUT
U2 V2 W2
1)
2)
U1 V1 W1
3~
Motor
1) 360 degrees grounding Grounding of 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
2) Use a separate grounding cable if the 360 degrees grounding

conductivity of the cable shield is less than 50%
of the conductivity of the phase conductor in a
cable with no symmetrically constructed Conductive gaskets
grounding conductor (see the document ACS800
multidrive: Planning the Electrical Installation • or ground the cable by twisting the shield as follows:
[3AFE 64783742, English]). flattened width > 1/5 × length.
Note:
If there is a symmetrically constructed grounding
conductor in the motor cable in addition to the b > 1/5 × a
conductive shield, connect the grounding conductor
to the grounding terminal at the drive and motor
b
ends. a
Do not use an asymmetrically constructed motor
cable. Connecting its fourth conductor at the motor
end increases bearing currents and causes extra
wear.
27
Conductor stripping lengths

Strip the conductor ends as follows to fit them inside the power cable connection
terminals.
Stripping length
Frame size
mm in.
R2i, R3i 10 0.39
R4i, R5i 16 0.63
Cable connection procedure

Refer to the diagram above.
1. Run the cable into the cubicle through the grommets provided.
2. Remove the cover of the connection box on the inverter module.
3. Strip off the plastic sheath of the motor cables under the cable clamps. Fasten the
clamps onto the stripped part of the cable.
4. (Frame sizes R2i and R3i) Crimp a lug terminal onto the twisted shield of the
cable.
(All frame sizes) Connect the shield to a grounding terminal. Keep the length of
the twisted shield as short as possible.
5. Connect the phase conductors of the motor cable to the U2, V2 and W2
terminals.
6. Secure the cable outside the unit mechanically.
7. Connect the control cables as described in section Connecting the control cables
– Frame R2i to R5i.
8. Refit the connection box cover.
28
Frame R2i to R4i power connections

Frame R3i pictured with connection box cover removed.
Item No. Information
1…3 Prevention of unexpected start (optional).

(See also the chapter Circuit diagrams.) If
present, this is wired at the factory.
3 2 1
U2 V2 W2 4 Strip off the outer sheathing of the cable at
the clamp.
Motor cable
clamp
Frame R5i power connections
Item No. Information
1…3 Prevention of unexpected start (optional).

(See also the chapter Circuit diagrams.) If
present, this is wired at the factory.
U2 V2 W2 4 Strip off the outer sheathing of the cable at

the clamp.
3
1 2
Motor cable
clamp
29
Power connections – Frame R7i
Diagram
Inverter module
OUTPUT
U2 V2 W2
U2 V2 W2
Cabinet PE
*)
V1
U1 W1
3~
Motor
*Use a separate grounding cable if the conductivity Grounding of the motor cable shield at the motor end
of the cable shield is less than 50% of the For minimum radio frequency interference:
conductivity of the phase conductor in a cable with
• ground the cable shield 360 degrees at the lead-through of
no symmetrically constructed grounding conductor
the motor terminal box
(see the document ACS800 MultiDrive; Planning
the Electrical Installation [3AFE 64783742,
English]).
Note: 360 degrees grounding
If there is a symmetrically constructed grounding
conductor in the motor cable in addition to the
conductive shield, connect the grounding conductor Conductive gaskets
to the grounding terminal at the drive and motor
ends. • or ground the cable by twisting the shield as follows:
flattened width > 1/5 × length.
Do not use an asymmetrically constructed motor
cable. Connecting its fourth conductor at the motor
end increases bearing currents and causes extra
wear. b > 1/5 × a
b
a
30
Cable connection procedure

Refer to the diagram above.
1. Run the cable into the cubicle through the cable lead-throughs provided. Remove
shrouding if necessary.
2. Crimp suitable lug terminals onto the twisted shield and the conductors of the
cable.
3. Connect the shield (and any grounding conductors) of the motor cable to the PE
busbar close to the cable lead-through.
4. Connect the phase conductors of the motor cable to the U2, V2 and W2
terminals.
5. Secure the cable mechanically.
6. Connect the control cables as described in section Connecting the control cables
– Frame R7i (page 40).
7. Refit any shrouds that may have been removed during the procedure. Close the
cubicle door.
8. At the motor, connect the cables according to instructions from the motor
manufacturer. Pay special attention to the phase order.
31
Power connections – Frame R8i and multiples
Motor connection – Units without common motor terminal cubicle

Connection diagrams
The outputs of all parallel inverter modules within the same cubicle are optionally
interconnected at the factory for better redundancy.
With the optional interconnection, the motor cabling can be connected to the output
busbars at any module(s) in each inverter cubicle with the following limitations,
provided that the ampacity of the cables is sufficient. See the cabling examples
below.
PE
U2
V2
W2
U1
V1
M
W1 3~
U2 PE
V2
W2
Inverter unit cubicle
PE
U2
V2
U1
V1
M
W2
W1 3~
PE
U2
V2
W2
32
PE
U2
V2
W2
U2
V2
U1
V1
M
W2
W1 3~
PE
U2
V2
W2
PE
U2
V2
U1
V1
M
W2
W1 3~
PE
Note: The interconnecting

U2
busbars between the modules
V2
W2
are dimensioned to carry the
output current of one module
only.
U2
V2
W2
The recommended cable types are given in the document ACS800 multidrive: Planning the
Electrical Installation (3AFE64783742 [English]).
33
Without the optional interconnection, each module is cabled individually to the motor.
“Jumpering” the output cables from one inverter module to another (and then to the
motor) is allowed only if the modules are equipped with internal du/dt filters. See the
cabling examples below.
PE
U2
V2
W2
U1
V1
M
W1 3~
U2 PE
V2
W2
PE
U2
V2
U1
V1
M
W2
W1 3~
PE
U2
V2
Note: Allowed only if modules
W2 equipped with internal du/dt
filters (+E205).
PE
U2
V2
W2
U1
V1
M
W1 3~
U2 PE
V2
W2
34
Connection procedure
WARNING! The inverter modules are heavy and have a high centre of gravity. Be careful when
manoeuvring the modules. In order to minimise the danger of toppling over, keep the support legs
of the modules extended whenever manoeuvring the modules outside the cabinet.
Extract each inverter module from the cubicle as follows:

(1) Open the door of the inverter cubicle.
(2) Remove the shroud covering the upper part of the cubicle.
(3) Open the transparent cover on the front of the inverter module. Make note of the order of the fibre optic
cables and disconnect them. Move the cables aside.
(4) Remove the L-shaped DC busbars on top of the module.
(5) Disconnect the terminal block (X50, if present) next to the DC busbars.
(6) Remove the two module fastening screws (6a) at the top. At the base of the module, loosen the two
fastening screws (6b) but leave them in place; flip the bracket (6c) into the up position.
(7) Insert the module pull-out ramp under the two screws at the base of the module and tighten.
(8) Pull the module carefully out of the cubicle along the ramp. Make sure the wires do not catch.
(9) Extend the support legs of the module. Keep the legs extended until the module is about to be inserted
back into the cubicle.
6a
4
3
8
9a 9b
6c
6b
35
Lead the cables into the cabinet below each inverter module. Make the 360° earthing arrangement at the
cable entry as shown.
Grommet (in
IP54 units only)
Cut the cables to suitable length.
Strip the cables and conductors.
Twist the cable screens into bundles and connect to cabinet PE (ground) busbar.
Connect any separate ground conductors/cables to cabinet PE (ground) busbar.
Connect the phase conductors to the output terminals.
Insert each inverter module into the cubicle as follows:

(1) Move the inverter module close to the ramp, then retract the support legs of the module.
(2) Push the module back into the cubicle – mind your fingers.
(3) Refasten the module fixing screws at the top, reconnect the DC busbars.
(4) Reconnect the cables (X50 if present, fibre optic cables).
(5) Loosen the module fastening screws at the base of the module and remove the pull-out ramp. Flip the
module fastening bracket into the down position and tighten the screws.
Close the doors.
At the motor, connect the cables according to instructions from the motor manufacturer. Pay special
attention to the phase order.
36
Motor connection – Units with common motor terminal cubicle

Connection diagram
360° earthing is to be used at cable entries.
PE
U2
V2
U1
V1
M
W2
W1 3~
PE
Inverter unit cubicle Common motor terminal

cubicle
37
Lead the cables into the output cabinet. Make the 360° earthing arrangement at the cable entry as shown.
Grommet (in
IP54 units only)
Cut the cables to suitable length.
Strip the cables and conductors.
Twist the cable screens into bundles and connect to cabinet PE (ground) busbar.
Connect any separate ground conductors/cables to cabinet PE (ground) busbar.
Connect the phase conductors to the output terminals.
Close the doors.
At the motor, connect the cables according to instructions from the motor manufacturer. Pay special
attention to the phase order.
38
Connecting the control cables – Frame R2i to R5i

These inverter modules have a built-in RMIO (Motor control and I/O) board. For
descriptions of the terminals, see the chapter Motor control and I/O board (RMIO)
starting on page 47].
Frame R2i to R4i (R3i pictured)
Detachable I/O terminals (pull upwards)

The control cable connection
terminals are exposed when the
RMIO X39 for control
control panel platform (if present) is
panel cable
turned aside by pulling this lever. Be
careful – do not use excess force
when pulling.
Optional module 1
I/O cables: Ground the
control cable shields in the
holes with screws. See 360 Optional module 2
degrees grounding of I/O
cables on page 45
DDCS communication
option module 3:
RDCO
Install shroud
(included) on the relay
4
3
outputs if voltage at the

2
1
terminals exceeds
50 V AC
39
Frame R5i
Optional module 1
Optional module 2
RMIO X39 for
control panel cable
DDCS communication option
module 3: RDCO
Control cable Install shroud (included) on the

grounding: see 360 relay outputs if voltage at the
degrees grounding terminals exceeds 50 V AC
of I/O cables on
page 45
Detachable I/O terminals (pull
upwards)

The RMIO board of the inverter module can be powered from an external 24 V DC
supply. This is practical if the board needs to be kept live even if the main power to
the drive is off. The 24 V supply can be fed from a UPS if necessary.
Refer to chapter External +24 V power supply for the RMIO board, starting on page
53.
40
Connecting the control cables – Frame R7i

Inverter units consisting of frame R7i inverter modules employ a separate control
unit, RDCU-02C, containing the RMIO board. For the terminals of the RMIO board,
see the chapter Motor control and I/O board (RMIO). For further information on the
RDCU-02C, see the document RDCU-02(C) Drive Control Unit Hardware Manual
(3AFE 64636324 [English]).
The RDCU-02C is located in a vertical position next to the inverter module.

panel connection
24 V DC power input
LED indicators
Optional module slot 1
Detachable I/O terminals

DDCS
communication option
module 3: RDCO
Optical link to inverter

module
Turn the supply (rectifier) unit switch-disconnector into open position.
Release the door handle and open the door of the inverter cubicle.
Remove shrouding wherever necessary to access the cable entries and trunking. Run the cables into the
inside of the cabinet through the grommets provided.
Top entry units only: If several cables need to be run through one grommet, use Loctite 5221 (cat. no.
25551) under the grommet to seal the cable entry.
41
Units with EMI conductive cushions only:

Run the cables between the cushions as shown below. Strip the cable at this location to enable proper
connection of the bare shield and the cushions. Tighten the cushions firmly onto the cable shields.
Side view
Strain relief EMI conductive
cushions
Grommet Lead-through plate
If the outer surface of a cable shield is non-conductive, turn the shield inside out as shown below and
apply copper foil to keep the shielding continuous. Do not cut the grounding wire (if present).
Stripped cable Conductive surface of Stripped part covered

the shield exposed with copper foil
Copper foil
Cable shield Shielded twisted pair
Grounding wire
On top entry units, sort the cables so that the thinnest and thickest cables are at opposite ends of the
opening.
Top view
Thickest cable Thinnest cable
Run the cables to the RDCU control unit (or other connection point) using the existing cable trunking
wherever possible.
Cut the cables to suitable length. Strip the cables and conductors.
Twist the cable shields into bundles and connect them to the ground terminal nearest to the terminal block.
(There is a grounding busbar next to the RDCU unit.) Keep the unshielded portion of the cables as short
as possible.
Connect the conductors to appropriate terminals (see the chapter Motor control and I/O board (RMIO) and
the circuit diagrams delivered with the unit).
Refit any shrouding removed earlier. Close the cubicle door.
42
Connecting the control cables – Frame R8i and multiples

Inverter units consisting of frame R8i inverter modules employ a separate control
unit, RDCU-02C, containing the RMIO board. For the terminals of the RMIO board,
see the chapter Motor control and I/O board (RMIO). For further information on the
RDCU-02C, see the document RDCU-02(C) Drive Control Unit Hardware Manual
(3AFE 64636324 [English]).
The RDCU is normally installed in an upright position within a drive control cubicle
placed next to the inverter cubicle(s).

panel connection
24 V DC power input
LED indicators
Detachable I/O terminals

DDCS
communication option
module 3: RDCO
Optical link to inverter

module
43
Turn the supply (rectifier) unit switch-disconnector into open position.
Release the door handle and open the door of the control cubicle.
Run the cables into the inside of the cubicle through the grommets provided.
Top entry units only: If several cables need to be run through one grommet, use Loctite 5221 (cat. no.
25551) under the grommet to seal the cable entry.
Units with EMI conductive cushions only:

Run the cables between the cushions as shown below. Strip the cable at this location to enable proper
connection of the bare shield and the cushions. Tighten the cushions firmly onto the cable shields.
Side view
Strain relief EMI conductive
cushions
Grommet Lead-through plate
If the outer surface of a cable shield is non-conductive, turn the shield inside out as shown below and
apply copper foil to keep the shielding continuous. Do not cut the grounding wire (if present).

Copper foil
Grounding wire
On top entry units, sort the cables so that the thinnest and thickest cables are at opposite ends of the
opening.
Top view
Thickest cable Thinnest cable
Run each cable to the appropriate terminal block. Wherever possible, use the existing cable trunking in the
cabinet. Use sleeving wherever the cables are laid against sharp edges.
Cut the cables to suitable length. Strip the cables and conductors.
44
If connecting to the RDCU drive control unit: Remove the outer insulation of the cables where they pass
through the strain relief/grounding clamp below the RDCU. After running all the necessary control cables
through the clamp, tighten it.
Note: If the outer surface of a cable shield is non-conductive, turn the shield inside out as shown below
and apply copper foil to keep the shielding continuous. Do not cut the grounding wire (if present).

Copper foil
Grounding wire
If NOT connecting to the RDCU drive control unit: Twist the cable shields into bundles and connect them to
the ground terminal nearest to the terminal block. Keep the unshielded portion of the cables as short as
possible.
Connect the conductors to appropriate terminals (see the chapter Motor control and I/O board (RMIO) and
the circuit diagrams delivered with the unit).
Close the cubicle door.
45
360 degrees grounding of I/O cables

Insulation
4
3
2
1
Double-shielded cable Single-shielded cable
If 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.
Wiring the Prevention of unexpected start circuit

The Prevention of unexpected start circuit has been pre-wired at the factory so that
only an external switch and a pilot light are needed. These components should be
installed on a control desk and wired to a terminal block as shown in the circuit
diagrams included in the drive delivery.
46
Cabling of I/O and fieldbus modules
Module
Keep 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
Keep as short as
possible
Note 1: 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 not to cut the
grounding wire. Clamp as close to
the terminals as possible.
47
Installation of optional modules and PC

Optional modules (such as fieldbus adapter, I/O extension module and the pulse
encoder interface) are inserted in the optional module slot of the RMIO board and
fixed with two screws. See the appropriate optional module manual for cable
connections.
Fibre optic links

DDCS fibre optic links are provided by the RDCO module (optional) for PC tools,
master/follower link, NDIO, NTAC, NAIO and fieldbus adapter modules of type Nxxx.
See RDCO User’s Manual for the connections. Observe colour coding 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.
48
47

This chapter shows
• external control connections to the RMIO board for the the ACS800 Standard
Application Program (Factory Macro)
• specifications of the inputs and outputs of the board.
To which products this chapter applies

This chapter applies to ACS800 units which employ the RMIO board.
Note on cabinet-built ACS800 drives

The terminals of the RMIO board are optionally wired to terminal block X2. The
connections shown below apply also to terminal block X2 (the markings are identical
to the ones on the RMIO board).
Terminals of X2 accept cables from 0.5 to 4.0 mm2 (22 to 12 AWG). The tightening
torque for screw terminals is 0.4 to 0.8 Nm (0.3 to 0.6 lbf.ft). For disconnecting wires
from spring terminals, use a screwdriver with a blade thickness of 0.6 mm (0.024”)
and width of 3.5 mm (0.138”), e.g. Phoenix Contact SZF 1-0,6X3,5.
Note on external power supply
WARNING! If the RMIO board is supplied from an external power source, 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.

48
External control connections (non-US)

External control cable connections to the RMIO board for the ACS 800 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.
11 DIIL Start interlock (0 = stop) 4)
DI5 DI6 Operation
0 0 Set speed through AI1
X23
1 0 Constant speed 1 1 +24V Auxiliary voltage output, non-isolated,
0 1 Constant speed 2 2 GND 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
modules installed on the board. 1 RO2 Relay output 2: running
2 RO2
3 RO2
X27
1 RO3 Relay output 3: fault (-1)
Fault 2 RO3
3 RO3

49
External control connections (US)

External control cable connections to the RMIO board for the ACS 800 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 <
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
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
3) See par. group 12 CONSTANT
SPEEDS.
11 DIIL Start interlock (0 = stop) 4)
DI5 DI6 Operation
0 0 Set speed through AI1
X23
1 0 Constant speed 1 1 +24V Auxiliary voltage output, non-isolated,
0 1 Constant speed 2 2 GND 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
modules installed on the board. 1 RO2 Relay output 2: running
2 RO2
3 RO2
X27
1 RO3 Relay output 3: fault (-1)
Fault 2 RO3
3 RO3

50
RMIO board specifications

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

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

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

51
Relay outputs
Three programmable relay outputs
Switching capacity 8 A at 24 VDC or 250 VAC, 0.4 A at 120 VDC
Minimum continuous current 5 mA rms at 24 VDC
Maximum continuous current 2 A rms
Isolation test voltage 4 kVAC, 1 minute
DDCS fibre optic link

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

52
Isolation and grounding diagram
(Test voltage: 500 V AC)

X20
1 VREF-
2 AGND
X21
1 VREF+
2 AGND
3 AI1+
4 AI1- Common mode
voltage between
5 AI2+
channels ±15 V
6 AI2-
7 AI3+
8 AI3-
9 AO1+
10 AO1-
11 AO2+
12 AO2-
X22
1 DI1
2 DI2
3 DI3
4 DI4
Jumper J1 settings:
9 DGND1
5 DI5 All digital inputs share a common

J1
6 DI6 ground. This is the default setting.
7 +24VD
8 +24VD Grounds of input groups
11 DIIL DI1…DI4 and DI5/DI6/DIIL
or
are separate (isolation
10 DGND2 voltage 50 V).
X23
1 +24 V
2 GND
X25
1 RO1
2 RO1
3 RO1
X26
1 RO2
2 RO2
3 RO2
X27
1 RO3
2 RO3
3 RO3
(Test voltage:
4 kV AC)
Ground

53

This chapter describes how to connect external +24 V power supply for the RMIO
board.
When to use
External +24 V power supply for the RMIO board is recommended if
• the application requires fast start after connecting the input power supply
• fieldbus communication is required when the input power supply is disconnected.
For current consumption of the RMIO board, see chapter Motor Control and I/O
Board (RMIO).
Parameter settings
In Standard Application Program, set parameter 16.9 CTRL BOARD SUPPLY to
EXTERNAL 24V if the RMIO board is powered from an external supply.

54
Connecting +24 V external power supply – Frame R2i to R5i

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: + wire to terminal 1 and - wire to terminal 2.
8. Plug the connector in.
Frame sizes R2i to R4i Frame size R5i
4
4
3

55
6 7
5

56

57
Checklist
Check the mechanical and electrical installation of the drive before start-up. Go
through the checklist below together with another person.
Check that…
MECHANICAL INSTALLATION
There is sufficient free space around the unit. (See Technical data.)
The ambient operating conditions are allowed. (See Technical data.)
The unit is properly fastened to the floor. (See separate document ACS800 multidrive:
Mechanical Installation [3AFE 68233402, English])
The cooling air is able to flow freely.
The motor and the driven equipment are ready for start. (See Technical data: Motor
connection, and separate document ACS800 multidrive: Planning the Electrical Installation
[3AFE 64783742, English])
ELECTRICAL INSTALLATION (See Electrical installation, and separate document ACS800
multidrives (Cabinet-installed Drives); Mechanical Installation [3AFE 68233402, English])
The capacitors are reformed if stored over one year (refer to ACS 600/800 Capacitor
Reforming Guide [64059629, English]).
The drive is grounded properly.
The input voltage matches the nominal input voltage of the inverter unit.
The power connections at UDC+ and UDC– and their tightening torques are OK.
Appropriate DC fuses are installed.
The motor is of the correct voltage.
The star/delta connection in the motor terminal box is correct.
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 to the inverter unit are OK (including emergency stop and
Prevention of unexpected start wiring).
There are no tools, foreign objects or dust from drilling inside the modules or the cabinet.
58
Check that…
All shrouds and covers are in place.
59
Commissioning

This chapter describes the hardware commissioning of an ACS800 multidrive
inverter unit. For information on setting up the application program, refer to the
appropriate Firmware Manual. For information on commissioning the supply unit,
refer to its manual.
WARNING! The work described in this chapter must only be carried out by a
qualified electrician. The directions given in the document ACS800 Multidrive; Safety
Instructions (3AFE64760432 [English]) must be followed. Neglecting the safety
instructions can cause injury or death.
The installation of the drive system must be checked before commissioning the drive
unit(s).
Check that…
The mechanical and electrical installation of the drive system has been inspected and
approved. (See Installation checklist.)
The insulation resistance of the assembly has been checked according to instructions. (See
Electrical installation.)
Commissioning
60
Checks with no voltage connected

The table below is a commissioning checklist for the drive unit with no voltage
connected.
Action Information
WARNING! Ensure that the disconnector of the supply transformer is locked out,
i.e. no voltage is, or can be, connected to the drive system inadvertently. Check
also by measuring that no voltage is actually connected.
If the motor has a safety switch, make sure it is open. If the motor has no safety
switch, open the Prevention of unexpected start circuit (if present).
1. Drive data
Find out the following data for each drive unit and note
down any deviations from delivery documents.
Motor, pulse encoder and cooling fan rating plate data
correspond to the values in the motor list.
Motor temperature method: Pt100, PTC, other?
Motor fan of separately ventilated motors. Check the
current, the overcurrent protection setting and the
functioning of the fan output control circuit.
Direction of motor rotation.
Maximum and minimum speeds, fixed speeds.
Speed scaling factor, gear ratio, roll diameter, etc.
Acceleration and deceleration times.
Inertia compensation.
Operating modes (stop mode, etc.).
2. Voltage to cooling fans
Check that any circuit breakers and protection switches in See the circuit diagrams
the cooling fan supply circuit are closed. delivered with the drive.
3. APBU memory backup (units with parallel-connected inverter modules only)
Locate the PPCS branching unit (APBU-xx). Enable By default, memory backup is
memory backup battery by setting actuator 6 of switch S3 switched off to save the battery.
to ON.
Commissioning
61
Connecting voltage to auxiliary circuits

The table below describes how to connect voltage to the supply unit input terminals
and the auxiliary circuit for the first time.
Action Information
WARNING! Make sure it is safe to connect voltage to the input terminals. Ensure
that while the voltage is connected
• nobody is working on the unit or circuits that are wired from outside circuits to the
drive system
• the cabinet doors are closed.
Disconnect any auxiliary voltage (230 or 115 V AC) cables
that lead from the terminal blocks to the outside of the
equipment and have not yet been checked. Also disconnect
any uncompleted wiring.
Disconnect the communication link between the drive Refer to the circuit diagrams
system and any overriding system. delivered with the drive.
Make sure the main contactor/air circuit breaker cannot be
switched on inadvertently by remote control.
Be ready to trip the main breaker of the supply transformer
in case something abnormal occurs.
Ensure all cabinet doors are closed.
Close the main breaker of the supply transformer. The input terminals of the drive
system are now energised.
Close the auxiliary voltage switch (F10). The auxiliary voltage circuit is
now energised.
Commissioning
62
Checks with auxiliary voltage connected

The table below is a commissioning checklist for the drive units with voltage
connected to the input terminals of the drive system, and to the auxiliary voltage
circuit.
Action Information
WARNING! This section includes instructions for checking/measuring circuits under
voltage. Only a qualified person is allowed to carry out the work. Appropriate and
approved measuring instruments must be used.
IF IN DOUBT, DO NOT PROCEED!
Ensure the actions described in the previous section
(Connecting voltage to auxiliary circuits) have been
completed.
1. Cooling fans
Check that the cooling fans rotate freely in the right A paper sheet set on the lower
direction, and the air flows upwards. gratings stays. The fans run
Notes: noiselessly.
• The cooling fan(s) of frame R2i to R5i, as well as R8i Note: With frame R8i inverter
inverter modules equipped with the +C126 option modules, it must be visually
(speed-controlled fan), will not rotate until the DC checked that the fan rotates in
voltage to the module is connected. the direction indicated by an
arrow on the fan housing.
• Depending on the wiring, it may be necessary to have
the supply unit powered before the fans can be started.
In this case, check the cooling fans after powering the
supply unit.
2. Parameters
Set the drive parameters for each inverter unit. See the appropriate Firmware
Manual.
Commissioning
63
Connecting voltage to inverter unit

The table below describes how to connect voltage to the inverter unit.
Action Information
WARNING! When connecting voltage to the supply unit, the DC busbars will
become live, as will all the inverters connected to the DC busbars.
Make sure it is safe to connect voltage to the supply unit. Ensure that
• nobody is working on the unit or circuits that are wired from outside circuits to the
drive system
• it is safe to start the motor
• the cabinet doors are closed.
WARNING!
Inverter units with a DC switch/disconnector (switch fuse):
When the DC switch fuse and the main breaker/contactor of the supply unit are
closed, the inverter unit is energised through the charging circuit even though the
DC fuses of the inverter unit (i.e. the fuses in the switch fuse) are removed. When
the DC switch fuse is open, the fuses in it can be removed and re-inserted.
Inverter units without a DC switch/disconnector (switch fuse):
If the inverter unit only has DC fuses without a switch fuse, all the inverter units with
the DC fuses in place will be energised when the main breaker/contactor closes. To
prevent this, remove the fuses from the inverter units which are to remain
unenergised before connecting voltage. When the main breaker/contactor of the
supply unit is closed (DC busbars are live), never remove or insert the DC
fuses of an inverter unit.
INVERTER UNITS EQUIPPED WITH DC SWITCH/DISCONNECTOR
Turn the DC switch/disconnector into ON position. As soon as the DC bus is
energised later on in this
procedure, the capacitor bank of
the inverter module is charged
automatically.
POWERING THE DC BUS
WARNING! Before closing the main contactor/air circuit breaker, make sure that a
sufficient inverter power is connected to the intermediate (DC) bus. As rules of
thumb,
• the sum power of the inverters connected must be at least 30% of the sum
power of all inverters
• the sum power of the inverters connected must be at least 30% of the rated
power of the brake unit (Pbr.max) (if present).
If the above-mentioned rules are not followed, the DC fuses of the connected
inverter units may blow, or the brake chopper (if present) may be damaged.
Commissioning
64
Ensure that the number of inverters connected to the DC See the WARNING above.
bus is sufficient.
Close the main contactor (or air circuit breaker) of the The DC bus is now powered,
supply unit. along with all inverters that are
connected to it.
Checks with voltage connected to inverter unit

The table below contains the basic checks on the inverter unit when voltage is
connected to it.
Action Information
Check the rotation direction of the motor.
Check the operation of the pulse encoder (if present). Refer to the user manual of the
pulse encoder interface module.
Check the functioning of the emergency stop function from
each operating location.
Check that the Prevention of unexpected start function (if Refer to the circuit diagrams
present) works. delivered with the drive system.
1. Stop the inverter using a Stop command and wait until the
motor has stopped completely.
2. Open the Prevention of unexpected start circuit. A start inhibit warning will be
displayed.
3. Give a Start command. The inverter should not start.
4. Reset the inverter.
Commissioning
65
Control from an overriding system

After the inverters have been commissioned and tested locally, functional tests from
the overriding system are performed. A checklist is presented below.
Action Information
1. Disconnect all voltages from the drive system.
2. Connect the communication link between the overriding Refer to the circuit diagrams
system and the inverter. delivered with the drive system.
3. Power up the drive system.
4. Check…
the start/stop functions
torque etc. references
alarm/fault words
function in case of a communication break
updating intervals of the application program
other relevant points of the application.
Disconnecting/Reconnecting an inverter unit

If disconnection or reconnection of an inverter unit is needed, proceed as follows.
Action Information
1. Disconnecting an inverter unit
1. Stop the inverter using a stop command and wait until the
motor has stopped completely.
2. Open the Prevention of unexpected start circuit (if present)
to prevent inadvertent starting.
3. Open the DC switch/disconnector (switch fuse) of the
inverter unit.
2. Reconnecting an inverter unit
1. Close the DC switch/disconnector (switch fuse) of the The capacitor banks of the
inverter unit. inverter modules are charged
automatically.
2. Close the Prevention of unexpected start circuit (if present). The inverter unit is ready for
operation.
Commissioning
66
Commissioning
67
Maintenance

This chapter contains preventive maintenance instructions, and a description of the
LEDs of the drive.
Safety instructions
Only a qualified electrician is allowed to perform the maintenance.
Before starting work on the drive system,
• isolate the drive system from the main supply
• open the switch-disconnectors and lock them out in the open position
• switch off any voltages connected to the I/O terminals
• wait for 5 minutes to let the intermediate circuit capacitors discharge
• ensure there is no dangerous voltage present by measuring the voltage on the
input, I/O and intermediate circuit (DC bus) terminals.
Maintenance
68
Maintenance intervals
This table lists the routine maintenance intervals recommended by ABB.
Maintenance Interval Instructions
Capacitor reforming Every year when stored See Capacitor reforming.
Depending on the dustiness of

Heatsink temperature check
the environment, every 6 to 12 See Heatsinks.
and cleaning
months
IP22 and IP42 units: Air filter

check; replacement if Every year
necessary See Checking and replacing
the air filters.
IP54 units: Air filter
Every year
replacement
Frame R4i and R5i inverter

modules: Change of Every 3 years See Cooling fans.
additional cooling fan
Frame R8i inverter modules:

Check and cleaning of power Every 3 years See Power connections (R8i).
connections
Main cooling fan change Every 6 years See Cooling fans.
Units with parallel- Locate the APBU unit. Switch

connected inverter modules: off the power to the unit.
APBU branching unit – Every 6 years Remove cover. Replace
Memory backup battery battery with a new CR 2032
renewal battery.
Frame R4i and larger

inverter modules: capacitor Every 10 years See Capacitors.
renewal
Redundancy (Reduced run capability)

If one of the parallel-connected inverter modules of an inverter unit must be taken
out of the cabinet for service, it is possible to continue operation using the remaining
modules at reduced power. Follow the steps below.
1. Read and repeat the steps in the safety instructions above.
2. Extract the module to be serviced from the cabinet. Follow the directions given on
page 34.
3. Fasten the air baffle provided with the unit to the top module guide to block airflow
through the empty module bay.
Maintenance
69
4. Units with DC switch fuses only: Locate the ASFC switch fuse controller and set
the fibre optic link to the absent module to “disabled” using the appropriate switch
(S1, S2 or S3).
Fibre optic links to 1 to 3 inverter modules
D IS
D IS
D IS
P W R
U D C
U D C
U D C
O N L Y .
E N
E N
E N
1 1 5 V
T A G E
V 5
V 6
V 3
V 4
V 1
V 2
W IT H
S W IT C H F U S E C O N T R O L L E R
T E D
C
C
R A
O L
A
A
D
S
IN V 1
IN V 2
IN V 3
S E
IV E
0 V
0 V
V
S 1
S 2
S 3
M
S T A T
S T A T
S T A T
B E U
X IM U
S T E M
6 0
: 6 9
B D R
X 8
6 4 7 3 9 6 1 1
2 3 0 V
:
IE C
M A
U L
A B
S Y
T O
S U P P L Y V O L T A G E (X 5 )
E X C IT A T IO N V O L T A G E
O P E R . T E M P E R A T U R E
2 3 0 V , 5 0 /6 0 H z , 4 0 m A
1 1 5 V , 5 0 /6 0 H z , 8 0 m A
C H A R G IN G C U R R E N T
S O L E N O ID C O N T R O L
M O N IT O R IN G IN P U T S
(X 1 - X 3 ) M A X 1 6 A D C
O U T P U T (X 5 ) 1 1 5 /2 3 0
V A C , M A X 2 A / 3 ,5 s
1 5 V D C , M A X 1 0 m A
A S F C -0 1 C
A U X 2
N S O L
L S O L
IR 1 +
IR 1 -
IR 2 +
IR 2 -
IR 3 +
IR 3 -
X 7
IN V 1
IN V 2
IN V 3
G N D
G N D
1 5 V
P E
R A T IN G S
O U T P U T (X 4 )
L
N
M A X + 7 0 ºC
3
1
2
3
4
5
6
1
2
3
1
2
3
1
2
3
1
2
X 2
X 5
X 1
X 3
X 4
F 1
B A R C O D E L A B E L
5. Make the necessary parameter adjustments in the drive firmware. Refer to the
appropriate Firmware Manual.
Reconnect the module after service in reverse order.
Checking and replacing the air filters

2. Open the cabinet doors.
3. Check the air filters and replace if necessary (see Technical data for the correct
filter types). The inlet (door) filters can be accessed by removing the fastener(s)
at the top of the grille, then lifting the grille and pulling it away from the door. The
outlet (roof) filter in IP54 units has a similar mechanism.
4. Check the cleanliness of the cabinet. Clean the interior of the cabinet if necessary
using a soft brush and a vacuum cleaner.
5. Close the cabinet doors.
Heatsinks
Heatsink fins pick up dust from the cooling air. Inverter modules run 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 as described in Cooling fans elsewhere in this chapter.
2. Blow clean, dry compressed air from bottom to top and simultaneously use a
vacuum cleaner at the air outlet to trap the dust. Note: Prevent the dust from
entering adjoining equipment.
3. Refit the cooling fan.
Maintenance
70
Cooling fans
The cooling fan lifespan is about 50 000 operating hours. The actual lifespan
depends on the drive usage and ambient temperature. See the appropriate ACS 800
firmware manual for an actual signal which indicates the hours of usage of the fan.
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 (R2i, R3i)

To remove the fan, release the retaining clips. Disconnect the cable. Install the fan in
reverse order.
Bottom view
Fan replacement (R4i)

1. Loosen the screws that fasten the fan mounting plate to the frame.
2. Shift the fan mounting plate to the left and pull the fan assembly 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.
2 2
1 1 4 4
4 4
Maintenance
71

To remove the fan, undo the fixing screws. Disconnect the cable. Install the fan in
reverse order.
Bottom view
Additional fan
Types -0004-2, 0005-2, -0011-2 to -0020-2, -0006-3, -0009-3, -0020-3 to -0030-3,
-0009-5, -0011-5, -0025-5 to -0040-5 have an additional fan.
Replacement (R2i, R3i)
Remove the front cover. To remove the fan, release the retaining clip (1). Disconnect
the cable (2, detachable terminal). Install the fan in reverse order.
Top view
1
2
Replacement (R4i, R5i)

Remove the front cover. 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.
Maintenance
72

1. Disconnect the wire plug.
2. Remove the two screws holding the fan unit.
3. Pull the fan unit slightly outwards, then downwards to free it.
4. Install new fan in reverse order.
Maintenance
73

2. Open the inverter cubicle doors.
3. Disconnect the fan wiring plug (1).
4. Remove the locking screws (2).
5. Pull the fan out along its sliding rails (3).
6. Install new fan in reverse order.
IP54 (UL type 12) fan replacement

1. Remove the front and back gratings of the fan cubicle by lifting them upwards.
2. Remove the shrouds by undoing the fastening screws.
3. Undo the fastening screws of the side/top cover of the fan.
4. Lift the side/top cover of the fan off.
5. Disconnect the fan supply wire connector from the cabinet roof (on top and
inside the cabinet).
6. Undo the fastening screws of the fan cassette at each corner.
7. Lift the fan cassette off.
8. Undo the cable ties on the top of the fan cassette.
9. Disconnect the cables (detachable terminals).
10. Remove the fan capacitor by undoing the fastening screw of the clamp.
Maintenance
74
11. Undo the fastening screws of the fan.

12. Pull the fan out.
13. Install the new fan and fan capacitor in reverse order to the above. Ensure that
the fan is centered and rotates freely.
2 2 4
1
3
2
2
3
7
6
5
5
10
9
8
8
9
8 8
12
11 11
Maintenance
75
Power connections (R8i)

2. Open the cabinet doors.
3. Extract one inverter module from the cabinet as described in the motor cable
connection procedures in the chapter Electrical installation.
4. Check the tightness of the cable connections at the quick connector. Use the
tightening torque table in Technical data.
5. Clean all contact surfaces of the quick connector and apply a layer of suitable
joint compound (e.g. Isoflex® Topas NB 52 from Klüber Lubrication) onto them.
6. Re-insert the inverter module.
7. Repeat steps 3 to 6 for all remaining R8i inverter modules.
Capacitors
The drive intermediate circuit employs several electrolytic capacitors. Their lifespan
is from 45 000 to 90 000 hours depending on drive loading and ambient
temperature. Capacitor life can be prolonged by lowering the ambient temperature.
It is not possible to predict a capacitor failure. Capacitor failure is usually followed by
a mains fuse failure or a fault trip. Contact ABB if capacitor failure is suspected.
Replacements are available from ABB. Do not use other than ABB-specified spare
parts.
Capacitor reforming
Reform (re-age) spare part capacitors once a year according to ACS 600/800
Capacitor Reforming Guide (code: 64059629).
LEDs
This table describes LEDs of the drive.
Where LED When the LED is lit
RMIO board * Red Drive in fault state

Green The power supply on the board is OK.
Control panel mounting platform Red Drive in fault state
Green The main +24 V power supply for the control panel and the
RMIO board is OK.
* the LEDs are not visible in frame sizes R2i to R5i
Maintenance
76
Maintenance
77
Technical data

This chapter contains the technical data for the ACS800-107 inverter units.
See also the chapter Dimensions.
Ratings, inverter modules used

Nominal No-overload Light-overload Heavy-duty
Inverter modules used
ratings use use use Frame
Inverter unit type
Icont.max Imax Pcont.max I2N PN I2hd Phd size
Qty Type
A A kW A kW A kW
UN = 400 V
ACS800-107-0003-3 5.1 6.5 1.5 4.7 1.5 3.4 1.1 R2i 1 ACS800-104-0003-3
ACS800-107-0004-3 6.5 8.2 2.2 5.9 2.2 4.3 1.5 R2i 1 ACS800-104-0004-3
ACS800-107-0005-3 8.5 10.8 3 7.7 3.0 5.7 2.2 R2i 1 ACS800-104-0005-3
ACS800-107-0006-3 10.9 13.8 4 10.2 4.0 7.5 3.0 R2i 1 ACS800-104-0006-3
ACS800-107-0009-3 13.9 17.6 5.5 12.7 5.5 9.3 4.0 R2i 1 ACS800-104-0009-3
ACS800-107-0011-3 19 24 7.5 18 7.5 14 5.5 R3i 1 ACS800-104-0011-3
ACS800-107-0016-3 25 32 11 24 11 19 7.5 R3i 1 ACS800-104-0016-3
ACS800-107-0020-3 34 46 15 31 15 23 11 R3i 1 ACS800-104-0020-3
ACS800-107-0025-3 44 62 22 41 18.5 32 15 R4i 1 ACS800-104-0025-3
ACS800-107-0030-3 55 72 30 50 22 37 18.5 R4i 1 ACS800-104-0030-3
ACS800-107-0040-3 72 86 37 69 30 49 22 R5i 1 ACS800-104-0040-3
ACS800-107-0050-3 86 112 45 80 37 60 30 R5i 1 ACS800-104-0050-3
ACS800-107-0060-3 103 138 55 94 45 69 37 R5i 1 ACS800-104-0060-3
ACS800-107-0105-3 147 220 75 141 75 110 55 R7i 1 ACS800-104-0105-3
ACS800-107-0125-3 178 252 90 171 90 133 55 R7i 1 ACS800-104-0125-3
ACS800-107-0145-3 208 311 110 200 110 156 75 R7i 1 ACS800-104-0145-3
ACS800-107-0175-3 250 374 132 240 132 187 90 R7i 1 ACS800-104-0175-3
ACS800-107-0210-3 289 400 160 280 160 218 110 R8i 1 ACS800-104-0210-3
ACS800-107-0260-3 370 506 200 355 200 277 132 R8i 1 ACS800-104-0260-3
ACS800-107-0320-3 487 642 250 450 250 351 200 R8i 1 ACS800-104-0320-3
ACS800-107-0390-3 565 773 315 542 315 423 250 R8i 1 ACS800-104-0390-3
ACS800-107-0510-3 741 1014 400 711 400 554 315 R8i 1 ACS800-104-0510-3
ACS800-107-0770-3 1111 1521 630 1067 630 831 450 2×R8i 2 ACS800-104-0390-3
ACS800-107-1030-3 1452 1988 800 1394 800 1086 630 2×R8i 2 ACS800-104-0510-3
ACS800-107-1540-3 2156 2951 1200 2070 1200 1613 900 3×R8i 3 ACS800-104-0510-3
ACS800-107-2050-3 2845 3894 1600 2731 1600 2128 1120 4×R8i 4 ACS800-104-0510-3
ACS800-107-2570-3 3537 4842 2000 3396 2000 2646 1400 5×R8i 5 ACS800-104-0510-3
ACS800-107-3080-3 4223 5780 2400 4054 2400 3159 1600 6×R8i 6 ACS800-104-0510-3
UN = 500 V
ACS800-107-0004-5 4.9 6.5 2.2 4.5 2.2 3.4 1.5 R2i 1 ACS800-104-0004-5
ACS800-107-0005-5 6.2 8.2 3 5.6 3.0 4.2 2.2 R2i 1 ACS800-104-0005-5
ACS800-107-0006-5 8.1 10.8 4 7.7 4.0 5.6 3.0 R2i 1 ACS800-104-0006-5
ACS800-107-0009-5 10.5 13.8 5.5 10.0 5.5 7.5 4.0 R2i 1 ACS800-104-0009-5
ACS800-107-0011-5 13.2 17.6 7.5 12.0 7.5 9.2 5.5 R2i 1 ACS800-104-0011-5
ACS800-107-0016-5 19 24 11 18 11 13 7.5 R3i 1 ACS800-104-0016-5
Technical data
78

Inverter unit type
Qty Type
A A kW A kW A kW
ACS800-107-0020-5 25 32 15 23 15 18 11 R3i 1 ACS800-104-0020-5
ACS800-107-0025-5 34 46 18.5 31 18.5 23 15 R3i 1 ACS800-104-0025-5
ACS800-107-0030-5 42 62 22 39 22 32 18.5 R4i 1 ACS800-104-0030-5
ACS800-107-0040-5 48 72 30 44 30 36 22 R4i 1 ACS800-104-0040-5
ACS800-107-0050-5 65 86 37 61 37 50 30 R5i 1 ACS800-104-0050-5
ACS800-107-0060-5 79 112 45 75 45 60 37 R5i 1 ACS800-104-0060-5
ACS800-107-0070-5 96 138 55 88 55 69 45 R5i 1 ACS800-104-0070-5
ACS800-107-0105-5 115 172 75 110 55 86 55 R7i 1 ACS800-104-0105-5
ACS800-107-0125-5 135 202 90 130 90 101 55 R7i 1 ACS800-104-0125-5
ACS800-107-0145-5 166 248 110 159 110 124 75 R7i 1 ACS800-104-0145-5
ACS800-107-0175-5 208 311 132 200 132 156 90 R7i 1 ACS800-104-0175-5
ACS800-107-0215-5 250 374 160 240 160 187 110 R7i 1 ACS800-104-0215-5
ACS800-107-0260-5 315 457 200 302 200 236 132 R8i 1 ACS800-104-0260-5
ACS800-107-0320-5 365 530 250 350 250 273 160 R8i 1 ACS800-104-0320-5
ACS800-107-0400-5 455 660 315 437 315 340 200 R8i 1 ACS800-104-0400-5
ACS800-107-0460-5 525 762 355 504 355 393 250 R8i 1 ACS800-104-0460-5
ACS800-107-0610-5 700 1016 500 672 500 524 355 R8i 1 ACS800-104-0610-5
ACS800-107-0910-5 1050 1524 710 1008 710 785 560 2×R8i 2 ACS800-104-0460-5
ACS800-107-1210-5 1372 1991 1000 1317 1000 1026 710 2×R8i 2 ACS800-104-0610-5
ACS800-107-1820-5 2037 2956 1450 1956 1450 1524 1120 3×R8i 3 ACS800-104-0610-5
ACS800-107-2430-5 2688 3901 2000 2580 1850 2011 1400 4×R8i 4 ACS800-104-0610-5
ACS800-107-3030-5 3343 4850 2400 3209 2400 2500 1600 5×R8i 5 ACS800-104-0610-5
ACS800-107-3640-5 3990 5790 2900 3830 2900 2985 2000 6×R8i 6 ACS800-104-0610-5
UN = 690 V
ACS800-107-0011-7 13 14 11 12 7.5 8.5 5.5 R4i 1 ACS800-104-0011-7
ACS800-107-0016-7 17 19 15 16 11 11 7.5 R4i 1 ACS800-104-0016-7
ACS800-107-0020-7 22 28 18.5 21 15 15 11 R4i 1 ACS800-104-0020-7
ACS800-107-0025-7 25 38 22 24 18.5 19 15 R4i 1 ACS800-104-0025-7
ACS800-107-0030-7 33 44 30 32 22 22 18.5 R4i 1 ACS800-104-0030-7
ACS800-107-0040-7 36 54 30 35 30 27 22 R4i 1 ACS800-104-0040-7
ACS800-107-0050-7 51 68 45 49 37 34 30 R5i 1 ACS800-104-0050-7
ACS800-107-0060-7 57 84 55 55 45 34 30 R5i 1 ACS800-104-0060-7
ACS800-107-0075-7 69 103 55 66 55 52 45 R7i 1 ACS800-104-0075-7
ACS800-107-0105-7 88 132 75 84 75 66 55 R7i 1 ACS800-104-0105-7
ACS800-107-0125-7 105 157 90 101 90 79 75 R7i 1 ACS800-104-0125-7
ACS800-107-0145-7 132 197 110 127 110 99 90 R7i 1 ACS800-104-0145-7
ACS800-107-0175-7 150 224 132 144 132 112 90 R7i 1 ACS800-104-0175-7
ACS800-107-0215-7 170 254 160 163 160 127 110 R7i 1 ACS800-104-0215-7
ACS800-107-0260-7 215 322 200 206 200 161 160 R8i 1 ACS800-104-0260-7
ACS800-107-0320-7 289 432 250 277 250 216 200 R8i 1 ACS800-104-0320-7
ACS800-107-0400-7 336 503 315 323 315 251 240 R8i 1 ACS800-104-0400-7
ACS800-107-0440-7 382 571 355 367 355 286 270 R8i 1 ACS800-104-0440-7
ACS800-107-0580-7 486 727 450 467 450 364 355 R8i 1 ACS800-104-0580-7
ACS800-107-0870-7 729 1091 710 700 710 545 500 2×R8i 2 ACS800-104-0440-7
ACS800-107-1160-7 953 1425 900 914 900 713 710 2×R8i 2 ACS800-104-0580-7
ACS800-107-1740-7 1414 2116 1400 1358 1400 1058 1000 3×R8i 3 ACS800-104-0580-7
ACS800-107-2320-7 1866 2792 1900 1792 1800 1396 1400 4×R8i 4 ACS800-104-0580-7
ACS800-107-2900-7 2321 3472 2300 2228 2200 1736 1600 5×R8i 5 ACS800-104-0580-7
ACS800-107-3490-7 2770 4144 2800 2659 2700 2072 2000 6×R8i 6 ACS800-104-0580-7
ACS800-107-4070-7 3232 4835 3200 3103 3100 2417 2400 7×R8i 7 ACS800-104-0580-7
Technical data
79

Inverter unit type
Qty Type
A A kW A kW A kW
ACS800-107-4650-7 3694 5526 3700 3546 3600 2763 2800 8×R8i 8 ACS800-104-0580-7
ACS800-107-5230-7 4155 6216 4200 3989 4000 3108 3100 9×R8i 9 ACS800-104-0580-7
ACS800-107-5810-7 4617 6907 4600 4432 4500 3454 3500 10×R8i 10 ACS800-104-0580-7
ACS800-107-6390-7 5079 7598 5100 4876 4900 3799 3800 11×R8i 11 ACS800-104-0580-7
ACS800-107-6970-7 5540 8288 5600 5319 5400 4144 4200 12×R8i 12 ACS800-104-0580-7
Symbols
Nominal ratings
Icont.max Continuous RMS output current. No overloadability at 40 °C.
Imax Maximum output current. Allowable for 10 seconds at start, otherwise as long as allowed
by drive temperature. Note: Maximum motor shaft power is 150% Phd .
Typical ratings for no-overload use
Pcont.max Typical motor power. The power ratings apply to most IEC 34 motors at nominal voltage
(400, 500 or 690 V).
Typical ratings for light-overload use (10% overloadability)
I2N Continuous rms current. 10% overload is allowed for 1 minute every 5 minutes.
PN Typical motor power. The power ratings apply to most IEC 34 motors at nominal voltage
(400, 500 or 690 V).
Typical ratings for heavy-duty use (50% overloadability)
I2hd Continuous rms current. 50% overload is allowed for 1 minute every 5 minutes.
Phd Typical motor power. The power ratings apply to most IEC 34 motors at nominal voltage
(400, 500 or 690 V).
Derating
The load capacity (current and power) decreases if the installation site altitude exceeds 1000 metres
(3300 ft), or if the ambient temperature exceeds 40 °C (104 °F).
Temperature derating
In the temperature range +40 °C (+104 °F) to +50 °C (+122 °F) the rated output current is decreased
1 % for every additional 1 °C (1.8 °F). The output current is calculated by multiplying the current given
in the rating table by the derating factor.
Example If the ambient temperature is +50 °C (+122 °F) the derating factor is 100% - 1 % · 10 °C =
90 % or 0.90. The output current is then 0.90 · I or 0.90 · I . °C
2N 2hd
Note: Icont.max rating is not allowed above 40 °C (104 °F).
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. If the installation site is higher than
2000 m (6600 ft) above sea level, please contact your local ABB distributor or office for further
information.
Technical data
80
DC capacitance, DC fuses, noise, cooling characteristics

DC Noise
DC fuses Power loss Air flow
Inverter unit type capacitance level
µF Qty Type (Bussmann) dBA W (Btu/h) m3/h (ft3/min)
UN = 400 V
ACS800-107-0003-3 350 2 170M1561 62 100 (340) 35 (21)
ACS800-107-0004-3 350 2 170M1561 62 120 (410) 35 (21)
ACS800-107-0005-3 350 2 170M1561 62 140 (480) 35 (21)
ACS800-107-0006-3 350 2 170M1561 62 160 (550) 35 (21)
ACS800-107-0009-3 350 2 170M1561 62 200 (680) 35 (21)
ACS800-107-0011-3 820 2 170M1564 62 250 (850) 69 (41)
ACS800-107-0016-3 820 2 170M1564 62 340 (1160) 69 (41)
ACS800-107-0020-3 820 2 170M1566 62 440 (1500) 69 (41)
ACS800-107-0025-3 1000 2 170M1566 62 530 (1810) 103 (61)
ACS800-107-0030-3 1000 2 170M1569 62 610 (2080) 103 (61)
ACS800-107-0040-3 2000 2 170M1569 62 810 (2770) 250 (147)
ACS800-107-0050-3 2000 2 170M1569 62 990 (3380) 250 (147)
ACS800-107-0060-3 2400 2 170M1570 62 1200 (4100) 250 (147)
ACS800-107-0105-3 4100 2 170M3818 72 1500 (5120) 480 (283)
ACS800-107-0125-3 6150 2 170M3818 72 1800 (6150) 480 (283)
ACS800-107-0145-3 6150 2 170M3819 72 2100 (7170) 480 (283)
ACS800-107-0175-3 6150 2 170M6810 72 2300 (7850) 480 (283)
ACS800-107-0210-3 8200 2 170M8545 72 2700 (9200) 1280 (750)
ACS800-107-0260-3 8200 2 170M8545 72 3700 (12700) 1280 (750)
ACS800-107-0320-3 10250 2 170M8552 72 4500 (15400) 1280 (750)
ACS800-107-0390-3 12300 2 170M8547 72 5800 (19800) 1280 (750)
ACS800-107-0510-3 14350 2 170M8550 72 7900 (27000) 1280 (750)
ACS800-107-0770-3 24600 4 170M8547 74 11000 (38000) 2560 (1510)
ACS800-107-1030-3 28700 4 170M8550 74 15000 (51000) 2560 (1510)
ACS800-107-1540-3 43050 6 170M8550 76 23000 (79000) 3840 (2260)
ACS800-107-2050-3 57400 8 170M8550 76 30000 (102000) 5120 (3010)
ACS800-107-2570-3 71750 10 170M8550 77 37000 (126000) 6400 (3770)
ACS800-107-3080-3 86100 12 170M8550 78 44000 (150000) 7680 (4520)
UN = 500 V
ACS800-107-0004-5 350 2 170M1561 62 120 (410) 35 (21)
ACS800-107-0005-5 350 2 170M1561 62 140 (480) 35 (21)
ACS800-107-0006-5 350 2 170M1561 62 160 (550) 35 (21)
ACS800-107-0009-5 350 2 170M1561 62 200 (680) 35 (21)
ACS800-107-0011-5 350 2 170M1561 62 250 (850) 35 (21)
ACS800-107-0016-5 820 2 170M1564 62 340 (1160) 69 (41)
ACS800-107-0020-5 820 2 170M1564 62 440 (1500) 69 (41)
ACS800-107-0025-5 820 2 170M1566 62 530 (1810) 69 (41)
ACS800-107-0030-5 1000 2 170M1566 62 610 (2080) 103 (61)
ACS800-107-0040-5 1000 2 170M1569 62 810 (2770) 103 (61)
ACS800-107-0050-5 2000 2 170M1569 62 990 (3380) 250 (147)
ACS800-107-0060-5 2000 2 170M1569 62 1200 (4100) 250 (147)
ACS800-107-0070-5 2400 2 170M1570 62 1400 (4800) 250 (147)
ACS800-107-0105-5 4100 2 170M1570 72 1500 (5120) 480 (283)
ACS800-107-0125-5 6150 2 170M3818 72 1800 (6150) 480 (283)
ACS800-107-0145-5 6150 2 170M3818 72 2100 (7170) 480 (283)
ACS800-107-0175-5 6150 2 170M3819 72 2400 (8200) 480 (283)
ACS800-107-0215-5 6150 2 170M6810 72 2600 (8880) 480 (283)
ACS800-107-0260-5 8200 2 170M8545 72 3300 (11300) 1280 (750)
Technical data
81
DC Noise
DC fuses Power loss Air flow
Inverter unit type capacitance level
3/h (ft3/min)
µF Qty Type (Bussmann) dBA W (Btu/h) m
ACS800-107-0320-5 8200 2 170M8545 72 3900 (13300) 1280 (750)
ACS800-107-0400-5 10250 2 170M8552 72 4700 (16100) 1280 (750)
ACS800-107-0460-5 12300 2 170M8547 72 5700 (19500) 1280 (750)
ACS800-107-0610-5 14350 2 170M8550 72 7700 (26300) 1280 (750)
ACS800-107-0910-5 24600 4 170M8547 74 11000 (38000) 2560 (1510)
ACS800-107-1210-5 28700 4 170M8550 74 15000 (51000) 2560 (1510)
ACS800-107-1820-5 43050 6 170M8550 76 22000 (75000) 3840 (2260)
ACS800-107-2430-5 57400 8 170M8550 76 29000 (99000) 5120 (3010)
ACS800-107-3030-5 71750 10 170M8550 77 36000 (123000) 6400 (3770)
ACS800-107-3640-5 86100 12 170M8550 78 43000 (147000) 7680 (4520)
UN = 690 V
ACS800-107-0011-7 670 2 170M2674 62 300 (1020) 103 (61)
ACS800-107-0016-7 670 2 170M2676 62 340 (1160) 103 (61)
ACS800-107-0020-7 670 2 170M2676 62 440 (1500) 103 (61)
ACS800-107-0025-7 670 2 170M2679 62 530 (1810) 103 (61)
ACS800-107-0030-7 670 2 170M2679 62 610 (2080) 103 (61)
ACS800-107-0040-7 670 2 170M2680 62 690 (2360) 103 (61)
ACS800-107-0050-7 1330 2 170M2680 62 840 (2870) 250 (147)
ACS800-107-0060-7 1330 2 170M2682 62 1000 (3400) 250 (147)
ACS800-107-0075-7 1530 2 170M2682 72 1100 (3760) 480 (283)
ACS800-107-0105-7 3070 2 170M4700 72 1500 (5120) 480 (283)
ACS800-107-0125-7 3070 2 170M4700 72 1800 (6150) 480 (283)
ACS800-107-0145-7 3070 2 170M6301 72 2300 (7850) 480 (283)
ACS800-107-0175-7 3070 2 170M6301 72 2500 (8540) 480 (283)
ACS800-107-0215-7 3070 2 170M6303 72 2900 (9900) 480 (283)
ACS800-107-0260-7 4600 2 170M8645 72 4000 (13700) 1280 (750)
ACS800-107-0320-7 6130 2 170M8646 72 4600 (15700) 1280 (750)
ACS800-107-0400-7 6130 2 170M8646 72 5200 (17800) 1280 (750)
ACS800-107-0440-7 7670 2 170M8647 72 6800 (23200) 1280 (750)
ACS800-107-0580-7 9200 2 170M8650 72 7400 (25300) 1280 (750)
ACS800-107-0870-7 15330 2 170M8647 74 13000 (44000) 2560 (1510)
ACS800-107-1160-7 18400 4 170M8650 74 14000 (48000) 2560 (1510)
ACS800-107-1740-7 27600 6 170M8650 76 21000 (72000) 3840 (2260)
ACS800-107-2320-7 36800 8 170M8650 76 28000 (96000) 5120 (3010)
ACS800-107-2900-7 46000 10 170M8650 77 35000 (120000) 6400 (3770)
ACS800-107-3490-7 55200 12 170M8650 78 42000 (143000) 7680 (4520)
ACS800-107-4070-7 64400 14 170M8650 78 49000 (167000) 8960 (5270)
ACS800-107-4650-7 73600 16 170M8650 79 55000 (188000) 10240 (6030)
ACS800-107-5230-7 82800 18 170M8650 79 62000 (212000) 11520 (6780)
ACS800-107-5810-7 92000 20 170M8650 79 69000 (236000) 12800 (7530)
ACS800-107-6390-7 101200 22 170M8650 79 76000 (260000) 14080 (8290)
ACS800-107-6970-7 110400 24 170M8650 79 83000 (283000) 15360 (9040)
Technical data
82
Input power connection

Voltage 510…560 V DC for 400 V units
510…675 V DC for 500 V units
710…930 V DC for 690 V units
Motor connection
Voltage (U2) 0 to U 1, 3-phase symmetrical, Umax at 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 Ratings, inverter modules used on page 77.
Power limit 2 × Phd. After approximately 2 minutes at 2 × Phd, the limit is set at Pcont.max.
Field weakening point 8 to 300 Hz
Switching frequency 3 kHz (average). In 690 V units 2 kHz (average).
Motor cable lead-throughs 3 × Ø60 mm at each R8i inverter module (units without common motor terminal cubicle)
(Frame R8i and multiples) Units with common motor terminal cubicle: See the chapter Dimensions.
Output terminals (Frames

R2i to R5i) U2, V2, W2 Earthing PE
Frame Max. wire Tightening Maximum Tightening
Cable Ø
size size torque wire size torque
mm2 AWG mm in. Nm lbf.ft mm2 AWG Nm lbf.ft
R2i 16* 6 21 0.83 1.2...1.5 0.9…1.1 10 8 1.5 1.1
R3i 16* 6 29 1.14 1.2...1.5 0.9...1.1 10 8 1.5 1.1
R4i 25 4 35 1.38 2…4 1.5…3.0 16 5 3.0 2.2
R5i 70 2/0 35 1.38 15 11.1 70 2/0 15 11.1
*16 mm 2 rigid solid cable, 10 mm2 flexible stranded cable
Technical data
83
Output terminals
Bottom exit
(Frame R7i)
except ACS800-107-0145-3, Front view
-0175-3, -0145-5, -0175-5, Bolt size: M12 or ½”
-0215-5, -0175-7 and -0215-7 Tightening torque: 70 Nm (52 lbf.ft)
with du/dt filters
Output terminals
Bottom exit
(Frame R7i)
ACS800-107-0145-3, -0175-3, Side view
-0145-5, -0175-5, -0215-5, Bolt size: M12 or ½”
-0175-7 and -0215-7 with du/dt Tightening torque: 70 Nm (52 lbf.ft)
filters
Technical data
84
Output terminals at each R8i

Bottom exit Top exit
inverter module (units without
common motor terminal Side view Side view
cubicle) Bolt size: M12 or ½” Bolt size: M12 or ½”
Tightening torque: 70 Nm (52 lbf.ft) Tightening torque: 70 Nm (52 lbf.ft)
Cabling
direction
Cabling direction
68265631-A0 cabinet_400_generic.asm
Output terminals (units with See the chapter Dimensions.

common motor terminal
cubicle)
Maximum recommended Max. motor cable length

Sizing method
motor cable length Motor control mode: DTC Motor control mode: Scalar
according to I2N and I2hd
according to Icont.max in R2i to R3: 100 m (328 ft) R2i: 150 m (492 ft)
ambient temperatures below R4i to R5i: 300 m (984 ft) R3i to R5i: 300 m (984 ft)
30 °C (86 °F)
according to Icont.max in R2i: 50 m (164 ft)
ambient temperatures above R3i and R4i: 100 m (328 ft)
30 °C (86 °F) R5i: 150 m (492 ft)
R7i: 300 m (984 ft)
–
R8i and multiples: 500 m (1640 ft)
Note: With cables longer than 100 m, the EMC Directive requirements may not be fulfilled.
Technical data
85
Efficiency
Approximately 98% at nominal power level
Cooling
Method Internal fans, flow direction from bottom to top
Filter material Inlet (door) Outlet (roof)

IP22/IP42 units Luftfilter airTex G150 –
IP54 units Luftfilter airComp 300-50 Luftfilter airTex G150
Free space around the unit See chapter Dimensions.
Cooling air flow See section DC capacitance, DC fuses, noise, cooling characteristics above.
Degree of protection
IP22; IP42; IP54; IP54R (with air duct outlet)
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
0 to 4000 m (13123 ft) above
sea level [above 1000 m
Installation site altitude - -
(3281 ft), see Derating on
page 79].
0 to +50 °C (32 to 122 °F).
-40 to +70 °C -40 to +70 °C
Air temperature No frost allowed. See
(-40 to +158 °F) (-40 to +158 °F)
Derating on page 79.
5 to 95% Max. 95% Max. 95%
Relative humidity No condensation allowed. Maximum allowed relative humidity is 60% in the presence of
corrosive gases.
No conductive dust allowed.
Boards without coating: Boards without coating: Boards without coating:
Contamination levels
Chemical gases: Class 3C1 Chemical gases: Class 1C2 Chemical gases: Class 2C2
(IEC 60721-3-3,
Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2
IEC 60721-3-2,
IEC 60721-3-1) 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
Technical data
86
70 to 106 kPa 70 to 106 kPa 60 to 106 kPa

Atmospheric pressure
0.7 to 1.05 atmospheres 0.7 to 1.05 atmospheres 0.6 to 1.05 atmospheres
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),
Vibration (IEC 60068-2)
max. 7 m/s2 (23 ft/s 2) max. 7 m/s2 (23 ft/s2) max. 15 m/s2 (49 ft/s 2)
(13.2 to 100 Hz) sinusoidal (13.2 to 100 Hz) sinusoidal (9 to 200 Hz) sinusoidal
Max. 100 m/s2 (330 ft/s2), Max. 100 m/s2 (330 ft/s2),
Shock (IEC 60068-2-29) Not allowed
11 ms 11 ms
250 mm (10 in.) for weight 250 mm (10 in.) for weight
under 100 kg (220 lb) under 100 kg (220 lb)
Free fall Not allowed
100 mm (4 in.) for weight 100 mm (4 in.) for weight
over 100 kg (220 lb) over 100 kg (220 lb)
Materials
Cabinet Hot-dip zinc-coated (thickness approx. 20 µm) sheet steel with polyester thermosetting
powder coating (thickness approx. 80 µm) on visible surfaces except back panel. Colour:
RAL 7035 (light grey, semigloss).
Busbars Tin- or silver-plated copper
Inverter modules • 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 (R2i and R3i)
• extruded aluminium AlSi (R4i and R5i)
Fire safety of materials Insulating materials and non-metallic items mostly self-extinctive.
(IEC 60332-1)
Packaging Frame of wood or plywood with PE-LD wrapping and PP or steel bands.
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.
Technical data
87
Applicable standards
The drive complies with the following standards. The compliance with the European Low
Voltage Directive is verified according to standards EN 50178 and EN 60204-1.
• EN 50178 (1997) Electronic equipment for use in power installations
• EN 60204-1 (1997) Safety of machinery. Electrical equipment of machines. Part 1: General requirements.
Provisions for compliance: The final assembler of the machine is responsible for installing
- an emergency-stop device
- a supply disconnecting device.
• EN 60529: 1991 (IEC 529), Degrees of protection provided by enclosures (IP code)
IEC 60664-1 (1992)
• EN 61800-3 (1996) + EMC product standard including specific test methods

Amendment A11 (2000)
• UL 508C UL Standard for Safety, Power Conversion Equipment, second edition
• CSA C22.2 No. 14-95 Industrial control equipment
Technical data
88
Technical data
89
Circuit diagrams

This chapter contains example circuit diagrams for different inverter units and
modules. For the wiring of a specific inverter unit, refer to the diagrams delivered
with the unit.
Circuit diagrams
90
R2i/R3i inverter modules – Block diagram
Circuit diagrams
91
R4i inverter module – Block diagram
Circuit diagrams
92
R5i inverter module – Block diagram
Circuit diagrams
93
R7i inverter module – Internal diagram

The diagram depicts an R7i inverter module with internal capacitor bank charging,
and the Prevention of unexpected start option.
Circuit diagrams
94
Circuit diagrams
95
R8i inverter module – Internal diagram

The diagram depicts an R8i inverter module with optional speed-controlled fan, and
the Prevention of unexpected start option.
Circuit diagrams
96
R8i inverter module – Charging circuit
Circuit diagrams
97
2×R8i inverter unit – Charging circuit
Circuit diagrams
98
3×R8i inverter unit – Charging circuit
Circuit diagrams
99
R8i inverter unit – I/O and control
Circuit diagrams
100
2×R8i inverter unit – I/O and control
Circuit diagrams
101
Example – Emergency stop (Category 1)
Circuit diagrams
102
Example – Prevention of unexpected start
Circuit diagrams
103
Dimensions

This chapter contains information on the general dimensions, weights and free
space requirements of ACS800-107 inverter units. For the dimensions of a specific
drive system, refer to the drawings delivered with the unit.
General cabinet dimensions

The inverter unit consists of cubicles built into a cabinet line-up. The cabinet has a
height of 2130 mm (83.86”) or 2315 mm (91.14”) (IP54). The standard depth is
689 mm (27.13”); some options – such as cooling air intake through the bottom of
the cabinet – increase the depth by 130 mm (5.12”).
The table below shows the provisional composition of cabinet line-ups for each
frame size and the standard combinations of options. The dimensions are in
millimetres.
Notes:
• The side panels increase the total line-up width by 30 millimetres (1.2”).
• Frame R2i to R7i inverter modules are housed in 400 mm-wide cubicles. Some
cabling or protection options may require additional cubicles. Refer to the actual
drawings delivered with the unit.
Cubicles in the line-up

Inverter unit width
R2i…R7i cubicle
terminal cubicle
terminal cubicle
Common motor
Common motor
Control cubicle
weight kg (lbs)
1×R8i inverter
2×R8i inverter
3×R8i inverter
2×R8i inverter
3×R8i inverter
3×R8i inverter
2×R8i inverter
3×R8i inverter
Shipping split
Approximate
Frame size
modules
modules
modules
modules
modules
modules
cubicles
module
widths
R2i…R7i 400* 400* <250 (550)

1×R8i 400 300 300 1000 1000 610 (1345)
2×R8i 600 300 300 1200 1200 800 (1760)
3×R8i 800 400 300 1500 1500 970 (2140)
4×R8i 600 400 600 300 1900 1900 1330 (2930)
5×R8i 800 400 600 300 2100 2100 1480 (3260)
6×R8i 800 600 800 300 2500 2500 1660 (3660)
7×R8i 600 600 600 800 300 2900 2900 2020 (4450)
8×R8i 800 600 400 400 800 300 3300 3300 2330 (5140)
9×R8i 800 800 400 400 800 300 3500 3500 2480 (5470)
10×R8i 800 600 600 400 800 600 300 4100 4100 2870 (6330)
11×R8i 800 800 600 600 800 600 300 2200+2300 4500 1540+1510 (3400+3330)
12×R8i 800 800 600 600 800 800 300 2200+2500 4700 1540+1660 (3400+3660)
*Frame R2i…R7i inverter modules are housed in 400 mm-wide cubicles. Depending on the size of the inverter modules in the delivery,
several inverter modules may share a single 400 mm cubicle.
Dimensions
104
Free space requirements

Front: Make sure there is enough room for the doors to open fully. For easy
maintenance, allow for room for supply/inverter module extraction and insertion.
Rear: None.
Left/Right: None; however, there should be enough room for the leftmost and/or
rightmost cabinet doors to open fully.
Top:
> 320 mm (12.3”) for

fan replacement
> 400 mm > 400 mm

(15.75”) (15.75”)
IP22/42 IP54
Dimensions
105
Common motor terminal cubicles

300 mm
Dimensions
106
400 mm
Dimensions
107
600 mm
Dimensions
108
Dimensions
3AFE68233453 REV C / EN
EFFECTIVE: 19.09.2005
ABB Oy
AC Drives
P.O. Box 184
FI-00381 HELSINKI
FINLAND
Telephone +358 10 22 11
Fax +358 10 22 22681
Internet http://www.abb.com

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ACS800

© 2005 ABB Oy. All Rights Reserved.

Introduction to this manual

Motor control and I/O board (RMIO)

External +24 V power supply for the RMIO board

Introduction to this manual

What this chapter contains

Introduction to this manual

Categorization according to the frame size

Introduction to this manual

Terms and abbreviations

CMF Common mode filtering.

DDCS Distributed Drives Communication System; a protocol used in optical fibre

Drive unit See Inverter unit.

DTC Direct Torque Control.

EMC Electromagnetic Compatibility.

IGBT Insulated Gate Bipolar Transistor; a voltage-controlled semiconductor type widely

PLC Programmable Logic Controller.

RFI Radio-Frequency Interference.

THD Total Harmonic Distortion

Introduction to this manual

Introduction to this manual

What this chapter contains

Typical drive system

Inverter unit hardware

Inverter module frames R2i to R5i

1 1 Control panel mounting platform and CDP

4 Slots for optional I/O modules

DC switch fuses for

Frame R2i inverter

Frame R5i inverter

Control and I/O cable

Inverter module frame R7i

Front view, with cooling

4 Power connection for cooling

5 Fibre optic connectors.

Frame R8i and multiples

4 Retractable support legs

Redundancy (Reduced run capability)

DC fuses for each

Fibre optic link from

The RDCU Drive Control Unit

The CDP-312R Control Panel

*Drive control unit

CDP 312R Control Panel Optional module 1: I/O extension (RAIO,

Optional module 2: I/O extension (RAIO,

Supply unit Inverter unit

Brake choppers and

1…6 Product series ACS800

8…10 Construction 107 Inverter unit

12…14 Size 0003 and up 3 kVA and up

16 Voltage rating 3 380/400/415 V. Nominal voltage: 400 V.

7 525/575/600/660/690 V. Nominal voltage: 690 V.

B Degree of protection – IP21 (UL type 1)

B053 IP22 (UL type 1)

B054 IP42 (UL type 1)

B055 IP54 (UL type 12)

H Cabling options H352 Bottom exit

H353 Top exit