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ACS800-11 Drives

5.5 to 110 kW

ACS800-U11 Drives

7.5 to 125 HP

Hardware Manual

3AFE68367883 Rev A EN

EFFECTIVE: 5.1.2005

Main Page

ACS800 Single Drive Manuals2
Safety Instructions5
What this Chapter Contains5
To Which Products this Chapter Applies5
Use of Warnings and Notes5
Installation and Maintenance Work6
- Grounding7
- Mechanical Installation and Maintenance8
- Printed Circuit Boards9
- Fibre Optic Cables9
Operation10
Permanent Magnet Motor11
- Installation and Maintenance Work11
- Start-Up and Operation11
  - Table of Contents13
  - Table of Contents18
About this Manual19
What this Chapter Contains19
Intended Audience19
Other Related Manuals19
Common Chapters for Several Products20
Categorization According to the Frame Size20
Categorization According to the Plus Code20
Contents20
Installation and Commissioning Flowchart21
Inquiries22
The ACS800-11/U1123
What this Chapter Contains23
Terms25
Operation Principle25
- Line-Side Converter25
AC Voltage and Current Waveforms26
Motor Control27
Printed Circuit Boards27
DDCS Communication Modules27
Main Circuit and Control Diagram28
Type Code29
Mechanical Installation31
Unpacking the Unit31
- Delivery Check31
Moving the Unit32
Before Installation33
- Requirements for the Installation Site33
Mounting the Drive on the Wall34
Cabinet Installation34
- Preventing Cooling Air Recirculation34
- Unit above Another35
Planning the Electrical Installation37
What this Chapter Contains37
To Which Products this Chapter Applies37
Motor Selection and Compatibility37
- Protecting the Motor Insulation and Bearings39
- Requirements Table40
Permanent Magnet Synchronous Motor42
Supply Connection42
- Disconnecting Device (Disconnecting Means)42
  - ACS800-01, ACS800-U1, ACS800-11, ACS800-U11, ACS800-02, ACS800-U2 Without Enclosure Extension, ACS800-04, ACS800-U442
  - ACS800-U2 with Enclosure Extension, ACS800-07 and ACS800-U742
- Fuses42
Thermal Overload and Short-Circuit Protection43
- Mains Cable (AC Line Cable) Short-Circuit Protection43
  - Acs800-04/U443
- Drive AC Fuses (ACS800-07/U7, and ACS800-02/U2 with Enclosure Extension)43
- Operating Time of the Fuses43
- Circuit Breakers44
Ground Fault Protection44
Emergency Stop Devices44
- ACS800-02/U2 with Enclosure Extension and ACS800-07/U744
  - Restarting after an Emergency Stop44
Prevention of Unexpected Start45
Selecting the Power Cables46
- General Rules46
- Alternative Power Cable Types47
- Motor Cable Shield47
- Additional US Requirements48
  - Conduit48
  - Armored Cable / Shielded Power Cable48
Power Factor Compensation Capacitors48
Equipment Connected to the Motor Cable49
- Installation of Safety Switches, Contactors, Connection Boxes, Etc49
  - Bypass Connection49
- Before Opening a Contactor (DTC Control Mode Selected)49
Protecting the Relay Output Contacts and Attenuating Disturbances in Case of Inductive Loads50
Selecting the Control Cables51
- Relay Cable51
- Control Panel Cable51
Connection of a Motor Temperature Sensor to the Drive I/O52
Routing the Cables52
- Control Cable Ducts53
Electrical Installation55
What this Chapter Contains55
Checking the Insulation of the Installation55
- Drive55
- Input Cable55
- Motor and Motor Cable55
IT (Ungrounded) Systems56
- Disconnecting the EMC Filter Capacitors56
Connecting the Power Cables57
- Diagram57
- Conductor Stripping Lengths58
- Allowed Wire Sizes, Tightening Torques58
- Wall Installed Units (European Version)58
  - Power Cable Installation Procedure58
- Wall Installed Units (US Version)61
- Warning Sticker62
Connecting the Control Cables63
- Terminals63
- 360 Degrees Grounding64
  - When the Outer Surface of the Shield Is Covered with Non-Conductive Material64
- Connecting the Shield Wires64
- Cabling of I/O and Fieldbus Modules65
- Pulse Encoder Module Cabling65
- Fastening the Control Cables and Covers66
Installation of Optional Modules and PC66
External +24 V Power Supply for the RMIO Board66
Motor Control and I/O Board (RMIO)67
What this Chapter Contains67
To Which Products this Chapter Applies67
Note for the ACS800-02 with Enclosure Extension and the ACS800-0767
Note on External Power Supply67
- External Control Connections (Non-US)68
- External Control Connections (US)69
RMIO Board Specifications70
- Analogue Inputs70
- Constant Voltage Output70
- Auxiliary Power Output70
- Analogue Outputs70
- Digital Inputs70
- Relay Outputs71
- DDCS Fibre Optic Link71
- 24 VDC Power Input71
Installation Checklist73
Checklist73
Operation75
What this Chapter Contains75
Start-Up and Use75
ACS800-11/U11 Specific Parameters in the IGBT Supply Control Program76
- Terms and Abbreviations76
- Parameters76
  - System Ctr Inputs76
  - 31 Automatic Reset76
- Fixed Parameters with the ACS800-11, ACS800-U11 and ACS800-1777
ACS800-11/U11 Specific Parameters in the Application Program78
- Terms and Abbreviations78
- Actual Signals and Parameters of the Line Converter in the Motor-Side Converter Control Program79
  - 09 Actual Signals79
  - 95 Hardware Specif79
Fieldbus Control Interface80
- Block Diagram: Reference Select80
Connection Diagram of the RMIO Board in the Line-Side Converter81
Fault Tracing82
- Fault: same ID Numbers82
Changing the Control Panel to the Line-Side Converter82
Changing the Control Panel to the Motor-Side Converter83
Maintenance85
What this Chapter Contains85
Safety85
Maintenance Intervals85
Heatsink86
Main Cooling Fan86
- Fan Replacement (R5, R6)87
Additional Fan87
- Replacement (R5)87
- Replacement (R6)88
Capacitors88
- Reforming88
Leds88
Technical Data89
IEC Ratings89
- Symbols90
- Sizing90
- Derating90
  - Temperature Derating90
  - Altitude Derating90
Mains Cable Fuses91
Cable Types92
Cable Entries92
Dimensions, Weights and Noise92
Input Power Connection93
Motor Connection93
Efficiency93
Cooling94
Degrees of Protection94
Ambient Conditions94
Materials95
Applicable Standards95
CE Marking96
- Definitions96
- Compliance with the EMC Directive96
- Compliance with the en 61800-3 + Amendment A11 (2000)96
  - First Environment (Restricted Distribution)96
  - Second Environment97
- Machinery Directive97
- C-Tick" Marking98
- Definitions98
- Compliance with IEC 61800-398
  - First Environment (Restricted Distribution)98
  - Second Environment99
Equipment Warranty and Liability99
US Tables100
- NEMA Ratings100
- Symbols100
- Input Cable Fuses101
- Cable Types102
- Cable Entries102
- Dimensions and Weights102
- UL/CSA Markings103
Dimensional Drawings105
Frame Size R5 (IP 21, UL Type Open)106
Frame Size R6 (IP 21, UL Type Open)107
External +24 V Power Supply for the RMIO Board109
What this Chapter Contains109
When to Use109
Parameter Settings109
Connecting +24 V External Power Supply110

ABB ACS800-11 - Page 3

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