ABB ACS800 Series

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ACS800-01 Drives

0.55 to 200 kW

ACS800-U1 Drives

0.75 to 200 hp

Hardware Manual

3AFE64382101 Rev K

EFFECTIVE: 2013-06-27

Main Page

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

ABB ACS800 Series - Page 3

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