ABB ACS800-01-0040-3 User Manual

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ACS800

Hardware Manual

ACS800-01 Drives (0.55 to 200 kW)

ACS800-U1 Drives (0.75 to 200 hp)

Table of Contents

Default Chapter2
- List of Related Manuals2
Safety Instructions5
- What this Chapter Contains5
- Use of Warnings and Notes5
- Installation and Maintenance Work6
- Operation9
- Permanent Magnet Motor10
Table of Contents19
Introduction to this Manual19
- What this Chapter Contains19
- Intended Audience19
- Categorization According to the Frame Size19
- Categorization According to the + Code19
- Contents20
- Installation and Commissioning Flowchart21
- Terms and Abbreviations22
Operation Principle and Hardware Description25
- What this Chapter Contains25
- Product Overview25
- Type Code26
- Main Circuit and Control27
Mechanical Installation29
- What this Chapter Contains29
- Unpacking the Unit29
  - Example 130
  - Example 231
- Checking the Delivery32
- Before Installation32
  - Requirements for the Installation Site32
- Mounting the Drive on the Wall34
- Cabinet Installation35
  - Preventing Cooling Air Recirculation35
  - Unit above Another36
Planning the Electrical Installation37
- What this Chapter Contains37
- Motor Selection and Compatibility37
  - Protecting the Motor Insulation and Bearings38
  - Requirements Table39
- Permanent Magnet Motor43
- Supply Connection44
- Thermal Overload and Short-Circuit Protection45
- Ground Fault Protection47
- Prevention of Unexpected Start-Up (Option +Q950)48
- Safe Torque off (Option +Q967)49
  - Safe Torque off Circuit Diagram50
- Selecting the Power Cables51
- Power Factor Compensation Capacitors54
- Equipment Connected to the Motor Cable54
  - Installation of Safety Switches, Contactors, Connection Boxes, Etc54
    - Bypass Connection54
- Using a Contactor between the Drive and the Motor55
- Protecting the Relay Output Contacts and Attenuating Disturbances in Case of Inductive Loads56
- Selecting the Control Cables57
  - Relay Cable57
  - Control Panel Cable57
- Connection of a Motor Temperature Sensor to the Drive I/O58
- Installation Sites above 2000 Metres (6562 Feet)58
- Routing the Cables58
  - Control Cable Ducts59
Electrical Installation61
- What this Chapter Contains61
- Checking the Insulation of the Installation61
- IT (Ungrounded) Systems62
- Connecting the Power Cables63
- Cabinet Installation (IP21, UL Type 1)70
  - Frame Size R570
  - Frame Size R671
- Connecting the Control Cables72
- Installation of Option Modules and PC76
  - Fibre Optic Link76
Installation of the AGPS Board (Prevention of Unexpected Start-Up, +Q950)77
- What this Chapter Contains77
- Prevention of Unexpected Start-Up (+Q950)77
- Installation of the AGPS Board77
  - Circuit Diagram80
- Start-Up and Validation81
- Use81
- Maintenance81
- Dimensional Drawing81
Installation of the ASTO Board (Safe Torque Off, +Q967)83
- What this Chapter Contains83
- Safe Torque off (+Q967)83
- Installation of the ASTO Board83
  - Circuit Diagram86
- Start-Up and Validation86
- Dimensional Drawing86
Motor Control and I/O Board (RMIO)87
- What this Chapter Contains87
- Note on Terminal Labelling87
- Note on External Power Supply87
- RMIO Board Specifications90
Installation Checklist93
- What this Chapter Contains93
- Checklist93
Start-Up and Use95
- What this Chapter Contains95
- Startup Procedure95
- Control Panel95
  - Removing the Control Panel95
Maintenance97
- What this Chapter Contains97
- Safety97
- Maintenance Intervals97
- Heatsink98
- Fan98
- Additional Fan102
- Capacitors103
  - Reforming103
- Leds103
Technical Data105
- What this Chapter Contains105
- IEC Data105
- NEMA Data118
- Input Power Connection123
- Motor Connection123
- Efficiency123
- Cooling124
- Degree of Protection124
- AGPS-11C (Option +Q950)124
- ASTO-11C (Option +Q967)124
- Ambient Conditions125
- Materials126
- Applicable Standards126
- CE Marking127
- Compliance with en 61800-3:2004127
  - Definitions127
- Marine Type Approvals129
- UL/CSA Markings130
  - UL Checklist130
- Disclaimer130
Dimensional Drawings131
- Frame Size R2 (IP21, UL Type 1)132
- Frame Size R2 (IP55, UL Type 12)133
- Frame Size R3 (IP21, UL Type 1)134
- Frame Size R3 (IP55, UL Type 12)135
- Frame Size R4 (IP21, UL Type 1)136
- Frame Size R4 (IP55, UL Type 12)137
- Frame Size R5 (IP21, UL Type 1)138
- Frame Size R5 (IP55, UL Type 12)139
- Frame Size R6 (IP21, UL Type 1)140
- Frame Size R6 (IP21, UL Type 1), -205-3 and -255-5 Units141
- Frame Size R6 (IP55, UL Type 12)142
- Frame Size R6 (IP55, UL Type 12) -0205-3 and -0255-5 Units143
- Dimensional Drawings (USA)144
- AGPS Board (Option +Q950)157
- ASTO Board with Enclosure (Option +Q967)158
Resistor Braking159
- What this Chapter Contains159
- Availability of Brake Choppers and Resistors for the ACS800159
- Selecting the Correct Drive/Chopper/Resistor Combination159
- Optional Brake Chopper and Resistor(S) for the ACS800-01/U1160
- Resistor Installation and Wiring162
- Protection of Frame Sizes R2 to R5 (ACS800-01/U1)163
- Protection of Frame Size R6163
- Brake Circuit Commissioning164
External +24 V DC Power Supply for the RMIO Board Via Terminal X34165
- What this Chapter Contains165
- Parameter Settings165
- Connecting +24 V DC External Power Supply166
RDCO-01/02/03/04 DDCS Communication Option Modules169
- What this Chapter Contains169
- Overview169
  - Delivery Check170
- Module Layout170
- Installation170
- Installation Procedure171
- Technical Data171
Further Information173
- Product and Service Inquiries173
- Product Training173
- Providing Feedback on ABB Drives Manuals173
- Document Library on the Internet173

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ABB ACS800-01-0040-3 Specifications

General

Brand	ABB
Model	ACS800-01-0040-3
Category	DC Drives
Language	English

Summary

ACS800 Hardware Manual

Safety Instructions

General Safety Information and Warnings

Covers critical safety guidelines, warnings, and notes for safe drive operation.

Safety for Installation, Maintenance, and Operation

Details safety precautions for installation, maintenance, operation, and specific motor types.

Operation Principle and Hardware Description

Mechanical Installation Procedures

Mounting and Cabinet Installation Procedures

Planning the Electrical Installation

Motor Compatibility, Protection, and Electrical Connection Planning

Guides motor selection, protection, and planning for electrical connections and safety features.

Control Cable Management and Routing

Electrical Installation Procedures

Insulation Checks and Power Cable Connections

Covers insulation checks and procedures for connecting power cables.

Frame-Specific Cable Installation and Grounding

AGPS Board Installation (+Q950)

AGPS Board Installation, Circuit Diagram, and Start-up

Covers the installation, schematic, and validation of the AGPS board for safety.

ASTO Board Installation (+Q967)

ASTO Board Installation, Circuit Diagram, and Start-up

Details the installation, schematic, and validation of the ASTO board for STO safety function.

Motor Control and I/O Board (RMIO)

RMIO Board Connections, Specifications, and Diagrams

Installation Checklist

Pre-Start-up Installation Verification

A comprehensive checklist for verifying all installation steps before drive operation.

Start-up and Use

Drive Startup Procedure and Control Panel Operation

Maintenance Procedures

Routine Maintenance Schedule and Safety Precautions

Outlines maintenance intervals, tasks, and critical safety measures.

Component Maintenance: Heatsinks, Fans, and Capacitors

Technical Data

IEC Electrical Specifications, Fuses, and Cables

NEMA Ratings, Ambient Conditions, and Compliance

Resistor Braking

Brake Chopper, Resistor Selection, and Installation

Braking Protection and Commissioning Procedures

RDCO DDCS Communication Option Modules

RDCO Module Overview, Installation, and Technical Data

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