Manual ABB

ACS800
Hardware Manual
ACS800-37 Drives (55 to 2700 kW / 75 to 3000 HP)
ACS800-37 Drives
55 to 2700 kW (75 to 3000 HP)
Hardware Manual
3AFE68557925 REV B EN
EFFECTIVE: 01.11.2005
© 2005 ABB Oy. All Rights Reserved.

1
Update Notice
The notice concerns the following ACS800-37 Drives (55 Code: 3AUA0000059451 Rev A
to 2700 kW / 75 to 3000 HP) Hardware Manuals: Valid: from 01.02.2010 until the release of the next revision of
Code Revision Language the manual
3AFE68557925 B English EN Contents:
3AFE68643155 B German DE The headings in this update notice refer to the modified
subsections in the original English manual. Each heading also
3AFE68643163 B Spanish ES includes a page number and a classifier NEW, CHANGED, or
3AFE68576024 B French FR DELETED. The page number refers to the page number in the
original English manual. The classifier describes the type of
3AFE68643171 B Italian IT
the modification.
3AUA0000019310 C Russian RU
NEW (page 6): Safety / Installation and maintenance work

• After maintaining or modifying a drive safety circuit or changing circuit boards
inside the module, retest the functioning of the safety circuit according to the
start-up instructions.
• Do not change the electrical installations of the drive except for the essential
control and power connections. Changes may affect the safety performance or
operation of the drive unexpectedly. All customer-made changes are on the
customer's responsibility.
[...]
Note:
• The Safe torque off function (option +Q968) does not remove the voltage from the
main and auxiliary circuits.
NEW (page 9): Safety / Operation

• The Safe torque off function (option +Q968) can be used for stopping the drive in
emergency stop situations. In the normal operating mode, use the Stop command
instead.
NEW (page 22): Terms and abbreviations

The following term has been added to the Terms and abbreviations table:
Term/ Explanation
Abbreviation
ASTO An optional board within drives used to implement the Safe torque off function
(option +Q968).
Update Notice
2
NEW/CHANGED (pages 40-41): Type code

The table below contains the valid option code definitions for the emergency stop.
Code Description
+Q951 Emergency stop, stop category 0 with opening the main contactor/breaker
+Q952 Emergency stop, stop category 1 with opening the main contactor/breaker
+Q963 Emergency stop, stop category 0 without opening the main contactor/breaker
+Q964 Emergency stop, stop category 1 without opening the main contactor/breaker SS1
NEW (pages 40-41): Type code

The table below contains the new option code definition for the Safe torque off
function.
Code Description
+Q968 Safe torque off (STO) with a safety relay
NEW (page 65): Emergency stop

Note: If you add or modify the wiring in the drive safety circuits, ensure that the
appropriate standards (e.g. IEC 61800-5-1, EN 62061, EN/ISO 13849-1 and -2) and
the ABB guidelines are met. After making the changes, verify the operation of the
safety function by testing it.
NEW (page 67): Safe torque off

The drive supports the Safe torque off (STO) function according to standards
EN 61800-5-2:2007; EN/ISO 13849-1:2008, IEC 61508, and EN 62061:2005. The
function also corresponds to an uncontrolled stop in accordance with category 0 of
EN 60204-1 and prevention of unexpected start-up of EN 1037.
The STO may be used where power removal is required to prevent an unexpected
start. The function disables the control voltage of the power semiconductors of the
drive output stage, thus preventing the inverter from generating the voltage required
to rotate the motor (see the diagram below). By using this function, short-time
operations (like cleaning) and/or maintenance work on non-electrical parts of the
machinery can be performed without switching off the power supply to the drive.
Update Notice
3
Update Notice
4
WARNING! The Safe torque off function does not disconnect the voltage of the main
and auxiliary circuits from the drive. Therefore maintenance work on electrical parts
of the drive or the motor can only be carried out after isolating the drive system from
the main supply.
Note: The Safe torque off function can be used for stopping the drive in emergency
stop situations. In the normal operating mode, use the Stop command instead. If a
running drive is stopped by using the function, the drive will trip and stop by coasting.
If this is not acceptable, e.g. causes danger, the drive and machinery must be
stopped using the appropriate stopping mode before using this function.
Note concerning permanent magnet motor drives in case of a multiple IGBT
power semiconductor failure: In spite of the activation of the Safe torque off
function, the drive system can produce an alignment torque which maximally rotates
the motor shaft by 180/p degrees. p denotes the pole pair number.
Note: If you add or modify the wiring in the drive safety circuits, ensure that the
appropriate standards (e.g. IEC 61800-5-1, EN 62061, EN/ISO 13849-1 and -2) and
the ABB guidelines are met. After making the changes, verify the operation of the
safety function by testing it.
NEW (page 103): On-load checks

The following information has been added to the procedure:
Action Additional information
Check the correct operation of the emergency stop

circuits from each operating location.
If the drive is equipped with the category 1
emergency stop function (option +Q952 or +Q964),
adjust the delay time of the emergency stop relay
and the deceleration time of the drive emergency
stop function. The factory default settings do not
necessarily meet the application needs.
NEW (page 103): On-load checks

The following information has been added to the procedure:
Check that the Safe torque off function (option Optional function. See delivery
+Q968, if installed) works: specific circuit diagrams.
• Ensure that the drive can be run and stopped

freely during the commissioning.
• Stop the drive (if running), switch the input power

off and isolate the drive from the power line by a
disconnector.
• Check the STO circuit connections against the

circuit diagram.
Update Notice
5
• Close the disconnector and switch the power on.
• Test the operation of the STO function when the

motor is stopped:
- Give a stop command for the drive (if running)

and wait until the motor shaft is at standstill.
- Activate the STO circuit and give a start

command for the drive.
- Ensure that the motor stays at standstill.
- Deactivate the STO circuit.
• Restart the drive and check that the motor runs

normally.
• Test the operation of the STO function when the

motor is running:
- Start the drive and ensure that the motor is

running.
- Activate the STO circuit.
- Ensure that the motor stops and the drive trips.
- Reset the fault and try to start the drive.
- Ensure that the motor stays at standstill.
- Deactivate the STO circuit.
• Restart the drive and check that the motor runs

normally.
CHANGED (page 122): LEDs

LED Indication
V309 (red) Prevention of unexpected start (option +Q950) or Safe torque off (option +Q968) is
ON.
NEW (page 136): Ambient conditions

Cabinets with option +Q968: the installation site altitude in operation is 0 to 2000 m.
Operation
installed for stationary use
Installation site altitude [...]

Cabinets with option +Q968:
0 to 2000 m
Update Notice
6
Update Notice
5
Safety instructions
What this chapter contains

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

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

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

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

These warnings are intended for all who work on the drive, motor cable or motor.
Ignoring the instructions can cause physical injury or death, or damage the
equipment.
WARNING!
• Only qualified electricians are allowed to install and maintain the drive.
• The main switch on the cabinet door does not remove the voltage from the input
busbars of the drive. Before working on the drive, isolate the whole drive from
the supply.
• Never work on the drive, the motor cable or the motor when main power is
applied. After switching off the input power, always wait for 5 min to let the
intermediate circuit capacitors discharge before you start working on the drive,
the motor or the motor cable. Measure the voltage between terminals UDC+
and UDC- (L+ and L–) with a multimeter (impedance at least 1 Mohm) to
ensure that the drive is discharged before beginning work.
• Apply temporary grounding before working on the unit.
• Do not work on the control cables when power is applied to the drive or to the
external control circuits. Externally supplied control circuits may cause
dangerous voltages to exist inside the drive even when the main power of the
drive is switched off.
• Do not make any insulation or voltage withstand tests on the drive or drive
modules.
• When reconnecting the motor cable, always check that the phase order is
correct.
• When joining shipping splits (if any), check the cable connections at the joints
before switching on the supply voltage.
• Live parts on the inside of the doors are protected against direct contact.
Special attention shall be paid when handling metallic shrouds.
Note:
• The motor cable terminals on the drive are at a dangerously high voltage when
the input power is on, regardless of whether the motor is running or not.
• The brake control terminals (UDC+, UDC-, R+ and R- terminals) carry a

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

may be present on the relay outputs of the drive system.
• The Prevention of Unexpected Start function does not remove the voltage from
the main and auxiliary circuits.
Safety instructions
7
WARNING!
• During the installation procedure, supply, filter or inverter modules may have to
be temporarily extracted from the cabinet. The modules have a high centre of
gravity. In order to minimise the danger of toppling over, keep the support legs
(if provided) of the modules extended whenever manoeuvring the modules
outside the cabinet. An overturning module can cause physical injury.
Do not tilt!
• Electrically conductive dust inside the unit may cause damage or lead to
malfunction. Make sure that dust from drilling does not enter the drive when
installing.
• Fastening the cabinet by riveting or welding is not recommended. However, if

welding is necessary, ensure the return wire is properly connected in order not
to damage the electronic equipment in the cabinet. Also ensure that welding
fumes are not inhaled.
• Ensure sufficient cooling of the unit.
• Cooling fans may continue to rotate for a while after the disconnection of the
electrical supply.
• Some parts inside the drive cabinet, such as heatsinks of power

semiconductors, remain hot for a while after the disconnection of the electrical
supply.
WARNING!
• The printed circuit boards contain components sensitive to electrostatic

discharge. Wear a grounding wrist band when handling the boards. Do not
touch the boards unnecessarily.
Safety instructions
8
Grounding
These instructions are intended for all who are responsible for the grounding of the
drive. Incorrect grounding can cause physical injury, death or equipment malfunction
and increase electromagnetic interference.
WARNING!
• Ground the drive, the motor and adjoining equipment to ensure personnel
safety in all circumstances, and to reduce electromagnetic emission and pick-
up.
• Make sure that grounding conductors are adequately sized as required by

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

earth (PE).
• Do not install a drive equipped with an EMC (line) filter to an ungrounded

power system or a high resistance-grounded (over 30 ohms) power system.
Note:
• Power cable shields are suitable for equipment grounding conductors only
when adequately sized to meet safety regulations.
• As the normal leakage current of the drive is higher than 3.5 mA AC or 10 mA

DC (stated by EN 50178, 5.2.11.1), a fixed protective earth connection is
required.
Fibre optic cables
WARNING!
• Handle the fibre optic cables with care. When unplugging optic cables, always
grab the connector, not the cable itself. Do not touch the ends of the fibres with
bare hands as the fibre is extremely sensitive to dirt. The minimum allowed
bend radius is 25 mm (1 in.).
Safety instructions
9
Operation
These warnings are intended for all who plan the operation of the drive or operate
the drive. Ignoring the instructions can cause physical injury or death or damage the
equipment.
WARNING!
• Before adjusting the drive and putting it into service, make sure that the motor
and all driven equipment are suitable for operation throughout the speed range
provided by the drive. The drive can be adjusted to operate the motor at
speeds above and below the speed provided by connecting the motor directly
to the power line.
• Do not activate automatic fault reset functions of the Standard Application

Program if dangerous situations can occur. When activated, these functions
will reset the drive and resume operation after a fault.
• Do not control the motor with the disconnecting device (means); instead, use
the control panel keys and , or commands via the I/O board of the drive.
The maximum allowed number of charging cycles of the DC capacitors (i.e.
power-ups by applying power) is five in ten minutes.
• Do not use the Prevention of Unexpected Start feature for stopping the drive
when the inverter unit(s) is running. Give a Stop command instead.
Note:
• If an external source for start command is selected and it is ON, the drive (with
Standard Application Program) will start immediately after fault reset unless the
drive is configured for 3-wire (a pulse) start/stop.
• When the control location is not set to Local (L not shown in the status row of
the display), the stop key on the control panel will not stop the drive. To stop
the drive using the control panel, press the LOC/REM key and then the stop
key .
Safety instructions
10
Permanent magnet motor drives

These are additional warnings concerning permanent magnet motor drives.
WARNING! Do not work on the drive when the permanent magnet motor is rotating.
Also when the supply power is switched off, a rotating permanent magnet motor
feeds power to the intermediate circuit of the drive and also the supply connections
become live (even when the inverter is stopped!).
Installation and maintenance work

• Disconnect the motor from the drive with a safety switch
and additionally, if possible,
• lock the motor shaft and ground the motor connection terminals temporarily by
connecting them together as well as to the PE.
Operation
Do not run the motor above the rated speed. Motor overspeed leads to overvoltage
which may result in explosion of the capacitors in the intermediate circuit of the drive.
Application program
Controlling a permanent magnet motor is only allowed using the ACS800 Permanent
Magnet Synchronous Motor Drive Application Program, or using other application
programs in scalar control mode only.
Safety instructions
11
Table of contents
Safety instructions
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Usage of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fibre optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Permanent magnet motor drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Application program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Table of contents
About this manual

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Common chapters for multiple products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Categorization according to the frame size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation and commissioning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
The ACS800-37
The ACS800-37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Cabinet line-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Frame R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Frame R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Frame R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Swing-out frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Cabling direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Single-line circuit diagram of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Line-side converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
AC voltage and current waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Motor-side converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Reduced run capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Control interfaces of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Table of contents
12
Door switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Main switch-disconnector (Q1 in frame size R6 to R8i) . . . . . . . . . . . . . . . . . . . . . . . . .36
Air circuit breaker (Q1 in frame size 2×R8i and up) . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Auxiliary power switch (Q100 in frame size 2×R8i and up) . . . . . . . . . . . . . . . . . . . . . .36
Earthing switch (Q9 in frame size 2×R8i and up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Other door switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
To control the supply unit… . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
To control the inverter unit… . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Fieldbus control of the line-side converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Block diagram: reference select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Frame sizes R6, R7i and R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Frame sizes 2×R8i to 6×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Mechanical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Moving the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
…by crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
…by fork-lift or pallet truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
…on rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Laying the unit on its back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Final placement of the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Fastening the cabinet to the floor (Non-marine units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Holes inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Fastening the unit to the floor and wall (Marine units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Joining the shipping splits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Connecting the DC busbars and the PE busbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
DC busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
PE busbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Cable conduit in the floor below the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Cooling air intake through bottom of cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Electric welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Planning the electrical installation

Motor selection and compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
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Permanent magnet synchronous motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Supply (AC line) cable short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Earth fault (Ground fault) protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Emergency stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Restarting after an emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Prevention of unexpected start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Power factor compensation capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Equipment connected to the motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Installation of safety switches, contactors, connection boxes, etc. . . . . . . . . . . . . . . . . . . . . 70
Bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Before opening an output contactor (in DTC motor control mode) . . . . . . . . . . . . . . . . . . . . 71
Relay output contacts and inductive loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Coaxial cable (for use with Advant Controllers AC 80/AC 800) . . . . . . . . . . . . . . . . . . . . . . . 72
Connection of a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Installation sites above 2000 metres (6562 feet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Control cable ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Electrical installation
Option coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Input power connection – Frame R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Input power connection – Frame R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Input power connection – Frame size R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Input power connection – Frame size 2×R8i and up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Motor connection – Frame R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Motor connection – Frame R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Motor connection – Frame R8i units without option +E202 or +H359 . . . . . . . . . . . . . . . . . . . . . . .83
Motor connection – Frame R8i with option +E202 but without +H359 . . . . . . . . . . . . . . . . . . . . . . .84
Output busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Motor connection – Units with common motor terminal cubicle (+H359) . . . . . . . . . . . . . . . . . . . . .87
Motor connection – Frame 2×R8i and up without common motor terminal cubicle . . . . . . . . . . . . .88
Output busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
Control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Drive control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Supply unit control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Installation of optional modules and PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Cabling of I/O and fieldbus modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Cabling of pulse encoder interface module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Fibre optic links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Tap settings of the auxiliary voltage transformer (Frame R8i and up) . . . . . . . . . . . . . . . . . . . . . . .94
Installation of brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Motor control and I/O board (RMIO)

To which products this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Note on cabinet-installed ACS800 drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Note on terminal labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
External control connections (non-US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
External control connections (US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
RMIO board specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Analogue inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Constant voltage output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Auxiliary power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Analogue outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
DDCS fibre optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
24 VDC power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Installation checklist and start-up

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
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Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Start-up procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Basic checks with no voltage connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Connecting voltage to input terminals and auxiliary circuit . . . . . . . . . . . . . . . . . . . . . . . . . 102
Starting the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Checks with the supply unit running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Supply (line-side converter) program set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Application program set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
On-load checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
ACS800-37-specific parameters in the IGBT Supply Control Program . . . . . . . . . . . . . . . . . . . . . 104
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Fixed parameters with the ACS800-37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
ACS800-37-specific parameters in the application program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Actual signals and parameters of line-side converter in motor-side converter program . . . 107
Maintenance
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Reduced run capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Checking and replacing the air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Quick connectors (Frame R8i and up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Supply/Inverter module cooling fan replacement (Frame R6) . . . . . . . . . . . . . . . . . . . . . . . 112
Supply/Inverter module cooling fan replacement (Frame R7i) . . . . . . . . . . . . . . . . . . . . . . . 113
LCL filter module cooling fan replacement (Frame R7i) . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Supply and inverter module cooling fan replacement (Frame R8i and up) . . . . . . . . . . . . . 115
Module fan replacement procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
LCL filter cooling fan replacement (Frame R8i and up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
LCL filter fan replacement procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Cabinet fan replacement (Frame R6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Cabinet fan replacement (Frame R8i and up with IP21-42) . . . . . . . . . . . . . . . . . . . . . . . . . 117
Cabinet fan replacement (Frame R8i and up with IP54) . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Heatsinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Capacitor replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Other maintenance actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Power module replacement (Frame R8i and up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Fault Tracing
Faults and warnings displayed by the CDP-312R Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . 121
Warning/Fault message from unit not being monitored by control panel . . . . . . . . . . . . . . . 121
Conflicting ID numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
LEDs of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
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Technical data
IEC ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
NEMA ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
ACS800-37 frame sizes and power module types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
AC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
DC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Input power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Degrees of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Tightening torques for power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Compliance with the EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Compliance with the EN 61800-3 (2004) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
First environment (drive of category C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Second environment (drive of category C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
“C-tick” marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Compliance with the EN 61800-3 (2004) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
First environment (drive of category C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Equipment warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Dimensions
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Frame R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
Frame R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
Frame R8i (without option +E202) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
Frame size R8i (with option +E202) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
Frame size 2×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Frame size 3×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
Frame size 4×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Frame size 5×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
Table of contents
17
Frame size 6×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Resistor braking
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Resistor braking options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Chopper/Resistor combinations – Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Brake choppers – Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Brake resistors – Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
Verifying the capacity of the braking equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Custom resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Calculating the maximum braking power (Pbr) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Example 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Example 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Example 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
Custom resistor installation and wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Brake circuit commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Table of contents
18
Table of contents
19
About this manual

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

Some chapters in this manual apply to several products including the ACS800-37.
Other product types may be mentioned in these chapters.
Categorization according to the frame size

Some instructions, technical data and dimensional drawings which concern only
certain drive frame sizes are marked with the symbol of the frame size (such as
“2×R8i”, etc.). The frame size is not marked on the drive designation label. To
identify the frame size of your drive, see the rating tables in chapter Technical data.
Contents
The chapters of this manual are briefly described below.
Safety instructions gives safety instructions for the installation, commissioning,
operation and maintenance of the drive.
About this manual introduces this manual.
The ACS800-37 describes the drive.
Mechanical installation instructs how to move, place and mount the drive.
Planning the electrical installation provides advice on motor and cable selection, the
protective functions of the drive, and cable routing.
Electrical installation describes the cabling and wiring of the drive.
About this manual

20
Motor control and I/O board (RMIO) shows external control connections to the motor
control and I/O board and its specifications.
Installation checklist and start-up helps in checking the mechanical and electrical
installation of the drive.
Maintenance contains preventive maintenance instructions.
Fault Tracing contains troubleshooting instructions.
Technical data contains the technical specifications of the drive, e.g. ratings, frame
sizes and technical requirements, provisions for fulfilling the requirements for CE
and other markings and warranty policy.
Dimensions contains information on the dimensions of the drive.
Resistor braking describes how to select, protect and wire optional brake choppers
and resistors.
Installation and commissioning flowchart
Task See
Plan the installation. Technical data

Check the ambient conditions, ratings, required Planning the electrical installation
cooling air flow, input power connection, compatibility Option manuals (if optional equipment is
of the motor, motor connection, and other technical included)
data.
Select the cables.
Unpack and check the units. Mechanical installation

Check the type code indicated by the type The ACS800-37
designation label with the original order. If the drive is For instructions on how to disconnect the EMC/
about to be connected to an IT (ungrounded) system, RFI filtering, contact your local ABB
check that the drive is not equipped with EMC/RFI representative.
filtering +E202. Check that all necessary optional
If the converter has been non-operational for
modules and equipment are present and correct.
more than one year, the converter DC link
capacitors need to be reformed. Contact your
local ABB representative for more information.
Only intact units may be started up.
Check the installation site. Mechanical installation, Technical data
Route the cables. Planning the electrical installation: Routing the

cables
Mount the cabinet line-up. Mechanical installation
Check the insulation of the motor and the motor Electrical installation: Checking the insulation of
cable. the assembly
About this manual

21
Task See
Connect the power cables. Connect the control and Mechanical installation, Planning the electrical
the auxiliary control cables. installation, Electrical installation
Check the installation. Installation checklist and start-up
Commission the drive. Installation checklist and start-up and

appropriate firmware manual
Commission the brake chopper (if present). Resistor braking.
Inquiries
Address any inquiries about the product to the local ABB representative, quoting the
type code and serial number of the unit. If the local ABB representative cannot be
contacted, address inquiries to ABB Oy, AC Drives, PO Box 184, 00381 Helsinki,
Finland.
About this manual

22
Terms and abbreviations

Term/Abbreviation Explanation
AGPS Gate driver power supply board. An optional board within drives, used to
implement the Prevention of Unexpected Start function.
APBU Type of optical branching unit used for connecting parallel-connected

converter modules to the RDCU.
CMF Common mode filtering.
DDCS Distributed Drives Communication System; a protocol used in optical fibre

communication inside and between ABB drives.
Drive unit See Motor-side converter.
EMC Electromagnetic Compatibility.
Frame (size) Relates to the construction type of the component in question. For
example, several drive types with different power ratings may have the
same basic construction, and this term is used in reference to all those
drive types.
With the ACS800-37, the frame size of the drive indicates the quantity and
frame size of the inverter modules, e.g. “2×R8i”.
To determine the frame size of a drive type, see the rating tables in the
chapter Technical data.
IGBT Insulated Gate Bipolar Transistor; a voltage-controlled semiconductor type

widely used in inverters because of their easy controllability and high
switching frequency.
IGBT supply unit (ISU) See Line-side converter.
Inverter unit (INU) See Motor-side converter.
Line-side converter A converter that is connected to the supply network and is capable of
transferring energy from the network to the DC link of the drive. With
ACS800-37 drives of frame size R7i and above, the line-side converter is
also called the (IGBT) supply unit or the ISU.
Motor-side converter A converter that is connected to the motor and controls the motor
operation. With ACS800-37 drives of frame size R7i and above, the
motor-side converter is also called the inverter unit or INU.
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.
RFI Radio-Frequency Interference.
RMIO Motor control and I/O board. Contains the principal inputs and outputs of
the drive. The RMIO is contained within the RDCU drive control unit.
THD Total Harmonic Distortion.
About this manual

23
The ACS800-37

This chapter describes the construction of the drive in short.
The ACS800-37
The ACS800-37 is a cabinet-built, low-harmonic drive for controlling AC motors.
Cabinet line-up
The drive consists of one or more cubicles that contain the supply and motor
terminals, 1 to 6 IGBT supply module(s) forming the line-side converter, 1 to 6
inverter modules forming the motor-side converter, and optional equipment. (Frame
R6 drives employ an integrated supply/inverter module.) The actual arrangement of
the cubicles varies from type to type and the selected options. See also the chapter
Dimensions for the different line-up variations.
The ACS800-37
24
Frame R6
The picture below shows the main components of a frame R6 drive with the door
open, and with the swing-out frame closed (left) and open (right).
3 3
No. Description
1 Swing-out frame (see page 27)
12 12 2 Cable entries for power and control cables (bottom
cable entry/exit models)
3 Cable entries for power and control cables (top cable
8 10 8 10 entry/exit models)
4 Switch fuse
4 4
5 Auxiliary voltage transformer
6 Integrated line-side/motor-side converter module
7 Input terminals (bottom cable entry/exit models)
8 Input terminals (top cable entry/exit models)
9 Output terminals (bottom cable entry/exit models)
10 Output terminals (top cable entry/exit models)
6 11 Control unit (RDCU) for motor-side converter
12 Cabinet cooling fan
11
1
7 9
5 5
2 2
The ACS800-37
25
Frame R7i
The picture below shows the main components of a frame R7i drive with the door
and the swing-out frame open.
No. Description
1 Swing-out frame (see page 27) (not shown). The drive
control units for both converter modules are installed on
the swing-out frame.
2 Cable entries for power and control cables (bottom
cable entry/exit models)
11 8 6 1 3 Cable entries for power and control cables (top cable
entry/exit models)
4 Switch fuse
5 Auxiliary voltage transformer
10 6 Line-side converter module
7 LCL filter
8 Motor-side converter module
9 Input terminals
10 Output terminals (units without du/dt filtering +E205)
11 Output terminals (units with du/dt filtering +E205)
9 4
5 7
The ACS800-37
26
Frame R8i
The picture below shows the main components of a frame R8i drive with the doors
open.
No. Description
1 Swing-out frame (see picture on page 27)
2 Supply unit controller (RDCU)
4 3 Inverter unit controller (RDCU)
5 4 Switch-disconnector*
8 5 Input contactor*
6 LCL filter
7 IGBT supply module
2
8 Intermediate DC link
3
9 Inverter module
6 7 9 10 Cooling fan for LCL filter
11 Cooling fan for IGBT supply module
12 Cooling fan for inverter module
13 Auxiliary voltage transformer (accessible by opening
14 the swing-out frame)
1 14 Auxiliary voltage circuitry (relays etc.)
13 *In larger drives, an air circuit breaker is used instead of the
switch-disconnector/contactor combination.
10 11 12
The ACS800-37
27
Swing-out frame
The swing-out frame provides space for the control circuitry of the drive as well as
optional electrical equipment. The frame can be opened by removing the two locking
screws (arrowed in the picture below) and moving the swing-out frame aside.
Depending on the frame size of the drive, the actual equipment of the drive may
differ from what is depicted.
Remove screws (arrowed) to Swing-out frame open

open swing-out frame
Drive control unit

(RDCU) with I/O
terminal blocks
Space for optional

terminal block X2
I/O cable entries into
Terminal block X1
swing-out frame
Mounting rails for

additional equipment
The ACS800-37
28
The following is a generic device layout diagram for the swing-out frame (drive frame
size R8i). The diagram is also attached to the inside of the cubicle door, with
installed devices marked. Refer to the circuit diagrams delivered with the drive for
device designations.
The ACS800-37
29
Cabling direction
The drawing below shows the available power cabling directions of the drive.
Frame size R6
6 3 Description
2 5 1 Input/Motor output – Bottom entry
IP21-42 IP54
2 Input/Motor output – Top entry (IP21-42)
3 Input/Motor output – Top entry (IP54)
4 Signal cable input/output – Bottom entry
5 Signal cable input/output – Top entry (IP21-42)
6 Signal cable input/output – Top entry (IP54)
1 4 1 4
Frame size R7i
Description
2 4 1 Input/Motor output – Bottom entry
2 Input/Motor output – Top entry
4 Signal cable input/output – Top entry
1 3
The ACS800-37
30
Frame size R8i
Description
2
10 11
4 6 8 A Input/output cubicle
B Supply and inverter unit cubicle
C Common motor terminal cubicle (optional)*
1 Standard input (bottom entry)

2 Standard input (top entry)
3 Standard output (bottom exit)
A B C
4 Standard output (top exit)
5 Optional output (bottom exit, 1st Environment)
6 Optional output (top exit, 1st Environment); additional depth 130 mm
7 Motor output – Bottom exit with common motor terminal cubicle (optional)*
8 Motor output – Top exit with common motor terminal cubicle (optional)*
10 Signal cable input/output – Top entry (IP54)
3 5 7
9 11 Signal cable input/output – Top entry (IP21-42)
1
*With EMC/RFI filtering for 1st Environment (+E202) only
Frame size 2×R8i and up
2
10 Description
4 6
A Auxiliary control cubicle
B Incoming cubicle
C Inverter unit cubicle
D Common motor terminal cubicle (optional)
1 Standard input (bottom entry)

2 Standard input (top entry)
3 Standard output (bottom exit); at each inverter module
4 Standard output (top exit); at each inverter module
A B C D
5 Motor output – Bottom exit with common motor terminal cubicle
(optional)
6 Motor output – Top exit with common motor terminal cubicle
(optional)
3 5 9 Signal cable input/output – Bottom entry

9
1 10 Signal cable input/output – Top entry
The ACS800-37
Supply unit Inverter unit Brake unit
DC bus
terminal cubicle.
M M
M M M M
Single-line circuit diagram of the drive
400 VAC 400 VAC 400 VAC 400 VAC

M M
230/400 VAC
230/115
VAC
M
Main
Supply M
3~
Charging
circuit
400 VAC
230/115 VAC
Note: This diagram represents a frame 2×R8i drive without a common motor
Ground fault supervision
Motor fan supply
The ACS800-37
31
32
Operation principle
The line-side and motor-side converters have their own RDCU control units and
control programs. The parameters of each program can be viewed and changed
using one control panel. The converter to be controlled can be selected using the
control panel; see the section Controls below.
Line-side converter
The line-side converter rectifies three-phase AC current to direct current for the
intermediate DC link of the drive. The intermediate DC link is further supplying the
motor-side converter that runs the motor.
The line-side converter is an active unit that, together with an LCL (inductor-
capacitor-inductor) filter, enables low harmonic distortion at the input terminals of the
drive.
By default, the line-side converter controls the DC link voltage to the peak value of
the line-to-line voltage. The DC voltage reference can be set also higher by a
parameter. The control of the IGBT power semiconductors is based on the Direct
Torque Control (DTC) method also used in the motor control of the drive. Two line
currents and the DC link voltage are measured and used for the control.
AC fuses LCL filter IGBT supply module
AC input Intermediate
DC link
The ACS800-37
33
AC voltage and current waveforms

The AC current is sinusoidal at a unity power factor. The IGBT supply unit does not
generate characteristic current or voltage overtones like a traditional 6- or 12-pulse
bridge does.
The Total Harmonic Distortion (THD) in voltage depends slightly on the Short Circuit
Ratio in the Point of Common Coupling (PCC). The high-frequency switching and
high du/dt slightly distort the voltage waveform at the input of the converter.
Typical line current (iU) and phase voltage (uU) waveforms are shown below.
I,U
uU
iU
t [ms]
An example spectrum and THD value of the current at the input of the drive are
shown below. Each harmonic is presented in percent of nominal current. n denotes
the ordinal number of the harmonic.
I [%] 10
0
THD 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 n
The ACS800-37
34
Motor-side converter
The motor control is based on the Direct Torque Control (DTC) method. Two phase
currents and DC link voltage are measured and used for the control. The third phase
control is measured for earth fault (ground fault) protection.
The motor-side converter is controlled by an RDCU drive control unit located in the
swing-out frame of the cabinet. The RDCU is connected to the inverter module(s) by
a fibre optic link, distributed through an optical branching unit. In the inverter
modules, the optic link connects to the AINT board, the terminals of which are
accessible through a hole on the front panel of the module.
Reduced run capability

This functionality is available for units with parallel-connected supply or inverter
modules only, i.e. frame sizes 2×R8i and up.
If one of the parallel-connected supply or inverter modules fails, the unit can
continue to be run at reduced power using the remaining modules. See page 110 for
information on utilising this feature.
The ACS800-37
Parameter setting and diagnostics through
CDP 312R Control Panel (and related
accessories).
Controls
Note: By default, the Control Panel of the

drive is set to control the inverter unit.
Drive Control Unit Drive Control Unit

(RDCU) (RDCU)
Motor Control Motor Control Optional module 1: I/O

and I/O Board and I/O Board extension (RAIO, RDIO),
pulse encoder interface
(RMIO) (RMIO)
(RTAC), or fieldbus
adapter (e.g. RMBA,
Control interfaces of the drive
RDNA, RPBA)
External control via

Optional module 2: I/O
analogue/digital
1 RESET G extension (RAIO, RDIO)
0 S E R ENC inputs and outputs
M
E
Y
or pulse encoder interface
(RTAC)
S TO P
RDCO RDCO Optional module 3:

Supply unit control circuitry CH0 CH1 DDCS communication
including door switches, Fibre optic link option (RDCO-01,
charging circuit control, RDCO-02 or RDCO-03)
main contactor control, etc.
Input power
= ~ To motor
~ =
Supply unit Inverter unit
The following diagram shows the control interfaces and I/O options of the drive.
Brake choppers and resistors (optional)
The ACS800-37
35
36
Door switches
Main switch-disconnector (Q1 in frame size R6 to R8i)
The switch-disconnector handle switches the main and auxiliary voltages to the drive
on and off.
Air circuit breaker (Q1 in frame size 2×R8i and up)
The air circuit breaker controls the main supply voltage (phases L1, L2 and L3). For
more information on using the breaker, refer to its manual.
WARNING! Opening the air circuit breaker will not switch off the auxiliary voltages of
the drive.
Auxiliary power switch (Q100 in frame size 2×R8i and up)

The auxiliary power switch controls all auxiliary voltages in the cabinet including the
DC link charging circuit. The auxiliary voltage switch must be closed before the drive
can be started.
Earthing switch (Q9 in frame size 2×R8i and up)
When closed, the optional earthing switch connects the supply phases L1, L2 and L3
to PE. The switch is interlocked so that it cannot be closed when the drive is
powered. Likewise, the drive will not start when the earthing switch is closed.
Other door switches
These switches are only installed if the drive is equipped with the optional
emergency stop function.
Start switch 1 Emergency stop button

G
0 = Cooling fans are disabled. (Other 0 S ER EN
EM
CY
auxiliary voltages are on.)

1 = Starts the cooling fans.
S = Closes the main contactor
and starts the supply unit.
STO P
Reset button RESET
Resets an emergency stop, after
which the supply unit can be started
using the start switch.
(Drive faults are reset via the drive
control panel or serial
communication)
The ACS800-37
37
Control panel
A control panel (type CDP-312R) is installed on the door of the drive. The CDP-312R
is the user interface of the supply unit (line-side converter) and the inverter unit
(motor-side converter) of the drive, providing the essential controls such as Start/
Stop/Direction/Reset/Reference, and the parameter settings for the units’ application
programs. More information on using the panel can be found in the Firmware Manual
delivered with the drive.
The control panel is wired to both the supply unit and the inverter unit using a
Y-splitter. The unit that is currently being controlled is indicated by the drive name on
the drive display; the suffix “MR” denotes inverter unit, “LR” denotes supply unit. The
control is switched between the units as follows:
To control the supply unit…
Step Action Press… Display (example)
1. To enter the Drive Selection Mode ACS 800 0490_3MR

Note: In local control mode, the motor-side converter trips DRIVE
if parameter 30.02 PANEL LOSS is set to FAULT. Refer to ASXR7xxx

ID-NUMBER 1
the appropriate application program firmware manual.
2. To scroll to ID number 2 ACS 800 0490_3LR
IXXR7xxx
ID-NUMBER 2
3. To verify the change to the line-side converter and display 2 -> 380.0 V
the warning or fault text ACT ACS 800 0490_3LR
** FAULT **
DC OVERVOLT (3210)
WARNING! The drive does not stop by pressing the control panel Stop key in local
control mode.
To control the inverter unit…

Step Action Press… Display (example)
1. To enter the Drive Section Mode ACS 800 0490_3LR

DRIVE
IXXR7xxx
ID-NUMBER 2
2. To scroll to ID number 1 ACS 800 0490_3MR
ACXR7xxx
ID-NUMBER 1
3. To verify the change to the motor-side converter 1 L -> 0.0 rpm I

ACT FREQ 0.00 Hz
CURRENT 0.00 A
POWER 0.00 %
The ACS800-37
38
Fieldbus control of the line-side converter

Fieldbus control of the line-side converter is performed via the motor-side converter
RMIO board as shown in the block diagram below.
Block diagram: reference select
The figure below shows the parameters for DC and reactive power reference
selection. AMC table contains actual values and parameters of the line converter.
11.02 Q REF SELECT
Inverter RMIO Line converter RMIO board PARAM 24.01

board
98.02 COMM. MODULE AI1
= INVERTER 24.03 Q POWER REF2 SEL AI2 24.01
Dataset 121 (CH1) AI3

Dataset 121 (CH0) Q POWER REF
MCW MCW (fixed) PERCENT
kVAr + PARAM 24.02
95.06 LCU Q POW REF Q-REF(fixed) 24.02 +
PHI
95.07 LCU DC REF (V) DC REF(fixed) COSPHI
Dataset 122 (CH1) Dataset 122 (CH0)

MSW MSW (fixed)
24.04
9.12 LCU ACT SIGNAL 1 106 (value)
9.13 LCU ACT SIGNAL 2 110 (value)
11.01 DC REF SELECT
Dataset 123 (CH1) Dataset 123 (CH0) PARAM 23.01

95.08 LCU PAR1 SEL 106
95.09 LCU PAR2 SEL 110 DC VOLT REF
AMC AI1
table AI2 23.01
AI3
FIELD BUS
MCW = Main Control Word

MSW = Main Status Word
The ACS800-37
39
Type code
The type code of the drive is indicated on the type designation label, attached on the
cabinet door. The type code contains information on the specifications and
configuration of the drive. The first digits from left express the basic configuration
(e.g. ACS800-37-0490-3). The optional selections are given thereafter, separated by
+ signs (e.g. +E202). The main selections are described below.
Note: The information below is for quick reference only and does not contain all
conditions and details. For more information, refer to ACS800 Ordering Information
(code: 64556568), available through ABB representatives.
Frame sizes R6, R7i and R8i
Selection Alternatives
Product series ACS800 product series
Type 37 = cabinet-mounted
Default configuration: IP21 (UL Type 1); main switch/disconnector with aR-
type AC fuses; 50 Hz supply; 230 V AC auxiliary voltage; RDCO-03 DDCS
Communication Option; CDP-312R Control Panel; EMC/RFI filtering for 2nd
Environment (+E200) (except frame R6); common mode filtering; Standard
Application Program; bottom entry/exit of cables; coated circuit boards; set of
English manuals.
Size Refer to Technical data: IEC ratings.
Voltage range 3 = 380/400/415 V AC
(nominal rating in bold) 5 = 380/400/415/440/460/480/500 V AC
7 = 525/575/600/690 V AC
+ options
Supply frequency A013 = 60 Hz
I/O options Refer to ACS800 Ordering Information (code: 64556568 [English]).
Fieldbus adapter
Application program
Degree of protection B053 = IP22 (UL Type 1)
B054 = IP42 (UL Type 1)
B055 = IP54 (UL Type 12) – Not available with +C134
B059 = IP54R with connection to air outlet duct
Construction C121 = Marine construction (reinforced mechanical parts and fastening,
marking of conductors [A1], door handles, self-extinctive materials)
C129 = UL Listed – Includes +H358
C134 = CSA Approved – Includes +H358
Resistor braking D150 = Brake chopper(s).
D151 = Brake resistors. Not available in IP54 or IP54R. Not available with
+C129 or +C134.
Filters E200 = EMC/RFI filtering for 2nd Environment (frame R6 only; standard with
frame R7i and R8i)
E202 = EMC/RFI filtering for 1st Environment TN (grounded) system,
restricted (A-limits). Only available for certain types. Not available for 690 V.
E205 = du/dt filtering
E206 = Sine filter – Not available with +C121 or +C129.
The ACS800-37
40
Cabling H351 = Top entry
H353 = Top exit
H358 = US/UK gland/conduit plate
H359 = Common motor terminal cubicle – Frame R8i with +E202 only
Auxiliary voltage G304 = 115 V AC – Standard with +C129 and +C134
Cabinet options G300 = Cabinet heaters (external supply) – Not available with +C129 or
+C134
G307 = Input terminals for external UPS-backed auxiliary voltage
G313 = Output for motor heater (external supply)
G330 = Halogen-free wiring and materials – Not available with +C129 or
+C134
Language of manuals Rxxx
Refer to ACS800 Ordering Information (code: 64556568 [English]).
Starter of auxiliary M600 = 1 … 1.6 A (1 pc)
motor fan M601 = 1.6 … 2.5 A (1 pc)
M602 = 2.5 … 4 A (1 pc)
M603 = 4 … 6.3 A (1 pc)
M604 = 6.3 … 10 A (1 pc) – Not for frame R6
M605 = 10 … 16 A (1 pc) – Not for frame R6
Safety features Q950 = Prevention of unexpected start (Category 3)
Q951 = Emergency Stop, Category 0
Q954 = Earth fault monitoring for IT (ungrounded) system
Special P902 = Customised (specified in Technical appendix on ordering)
P904 = Extended warranty
P913 = Special colour (specified in Technical appendix on ordering)
Frame sizes 2×R8i to 6×R8i
Product series ACS800 product series
Type 37 = cabinet-mounted
Default configuration: IP21 (UL Type 1); main switch/disconnector with aR-
type AC fuses, or air circuit breaker; 50 Hz supply; 230 V AC auxiliary
voltage; RDCO-03 DDCS Communication Option; CDP-312R Control Panel;
EMC/RFI filtering for 2nd Environment (+E200); du/dt filtering; common
mode filtering; Standard Application Program; bottom entry/exit of cables;
coated circuit boards; set of English manuals.
Size Refer to Technical data: IEC ratings.
Voltage range 3 = 380/400/415 V AC
(nominal rating in bold) 5 = 380/400/415/440/460/480/500 V AC
7 = 525/575/600/690 V AC
+ options
Supply frequency A013 = 60 Hz
I/O options Refer to ACS800 Ordering Information (code: 64556568 [English]).
Fieldbus adapter
Application program
Degree of protection B053 = IP22 (UL Type 1)
B054 = IP42 (UL Type 1)
B055 = IP54 (UL Type 12) – Not available with +C134
B059 = IP54R with connection to air outlet duct
The ACS800-37
41
Construction C121 = Marine construction (reinforced mechanical parts and fastening,
marking of conductors [A1], door handles, self-extinctive materials)
C129 = UL Listed – Includes +H358
C134 = CSA Approved – Includes +H358
Resistor braking D150 = Brake chopper(s).
D151 = Brake resistors. Not available in IP54 or IP54R. Not available with
+C129 or +C134.
Filters E202 = EMC/RFI filtering for 1st Environment TN (grounded) system,
restricted (A-limits). Only available for certain types. Not available for 690 V.
Note: EMC/RFI filtering for 2nd Environment (+E200) is standard equipment.
E206 = Sine filter – Not available with +C121 or +C129.
Line options F259 = Earthing switch – Not available with +C129
Cabling H351 = Top entry
H353 = Top exit
H358 = US/UK gland/conduit plate
H359 = Common motor terminal cubicle
Auxiliary voltage G304 = 115 V AC
Cabinet options G300 = Cabinet heaters (external supply) – Not available with +C129 or
+C134
G307 = Input terminals for external UPS-backed auxiliary voltage
G313 = Output for motor heater (external supply)
G317 = Busbar supply conductors
G330 = Halogen-free wiring and materials – Not available with +C129 or
+C134
Language of manuals Rxxx
Refer to ACS800 Ordering Information (code: 64556568 [English]).
Starter of auxiliary M602 = 2.5 … 4 A (1, 2 or 4 pcs)
motor fan M603 = 4 … 6.3 A (1, 2 or 4 pcs)
M604 = 6.3 … 10 A (1, 2 or 4 pcs)
M605 = 10 … 16 A (1 or 2 pcs)
M606 = 16 … 25 A (1 pc)
Safety features Q950 = Prevention of unexpected start (Category 3)
Q954 = Earth fault monitoring for IT (ungrounded) system
Q959 = Red-coloured trip pushbutton for external breaker
Special P902 = Customised (specified in Technical appendix on ordering)
P904 = Extended warranty
P913 = Special colour (specified in Technical appendix on ordering)
The ACS800-37
42
The ACS800-37
43

This chapter describes the mechanical installation procedure of the drive.
General
See chapter Technical data for allowable operating conditions and requirements for
free space around the unit.
The unit should be installed in an upright vertical position.
The floor that the unit is installed on should be of non-flammable material, as
smooth as possible, and strong enough to support the weight of the unit. The floor
flatness must be checked with a spirit level before the installation of the cabinets into
their final position. The maximum allowed deviation from the surface level is 5 mm in
every 3 metres. The installation site should be levelled, if necessary, as the cabinet
is not equipped with adjustable feet.
The wall behind the unit should be of non-flammable material.
Provide the drive with the amount of fresh cooling air given in Technical data.
Note: Very wide cabinet line-ups (> 4200 mm) are delivered as shipping splits.
Required tools
The tools required for moving the unit to its final position, fastening it to the floor and
tightening the connections are listed below.
• crane, fork-lift or pallet truck (check load capacity!); iron bar, jack and rollers
• Pozidrive and Torx (2.5–6 mm) screwdrivers for the tightening of the frame
screws
• torque wrench
• set of wrenches or sockets for joining shipping splits.
44
Moving the unit
…by crane
Use the steel lifting lugs attached to the top of
the cabinet. Insert the lifting ropes or slings into
the holes of the lifting lugs.
The lifting lugs can be removed (not mandatory)
once the cabinet is in its final position. If the
lifting lugs are removed, the bolts must be
refastened to retain the degree of protection
of the cabinet.
IP54 units
Allowed minimum height of lifting ropes or slings
for IP54 units is 2 metres.
45
…by fork-lift or pallet truck
The centre of gravity may be quite high. Be therefore careful

when transporting the unit. Tilting the cabinets must be
avoided.
The units are to be moved only in the upright position.
If using a pallet truck, check its load capacity before
attempting to move the unit.
…on rollers
(Not allowed with Marine versions)
Remove the wooden bottom frame which is part

of the shipment.
Lay the unit on the rollers and move it carefully
until close to its final location.
Remove the rollers by lifting the unit with a
crane, fork-lift, pallet truck or jack as described
above.
Laying the unit on its back
Cabinet back panel Support If the cabinet needs to be laid on its back, it
must be supported from below beside the
cubicle seams as shown.
46
Final placement of the unit

The cabinet can be moved into its final position with an
iron bar and a wooden piece at the bottom edge of the
cabinet. Care is to be taken to properly place the
wooden piece so as not to damage the cabinet frame.
47
Before installation
Delivery check
The drive delivery contains:
• drive cabinet line-up
• optional modules (if ordered) installed into the control rack at the factory
• ramp for extracting supply and inverter modules from the cabinet
• hardware manual
• appropriate firmware manuals and guides
• optional module manuals
• delivery documents.
Check that there are no signs of damage. Before attempting installation and
operation, check the information on the type designation label of the drive to verify
that the unit is of the correct type. The label includes an IEC and NEMA rating, C-UL
US, and CSA markings, a type code and a serial number, which allow individual
recognition of each unit. The first digit of the serial number refers to the
manufacturing plant. The next four digits refer to the unit’s manufacturing year and
week respectively. The remaining digits complete the serial number so that there are
no two units with the same serial number.
The type designation label is located on the supply unit door.
Each power module (i.e. supply and inverter module) is also individually labelled.
48
Installation procedure
1 See detailed instructions in the following few
pages.
(1) The cabinet can be installed with its back
against a wall, or back-to-back with another unit.
Fasten the unit (or first shipping split) to the floor
A with fastening clamps or through the holes inside
A
the cabinet. See section Fastening the cabinet to
the floor (Non-marine units).
With marine versions, fasten the unit (or first
shipping split) to the floor and wall/roof as
described in section Fastening the unit to the floor
and wall (Marine units).
Note: A clearance of 600 mm minimum above the
basic roof level of the cabinet (see inset on left) is
Top clearances required for cooling.
> 320 mm (12.3”)
for fan replace- Note: Leave some space at the left-hand and
ment
right-hand sides of the line-up (A) to allow the
> 400 mm > 400 mm
(15.75”) (15.75”) doors to open sufficiently.
IP22/42 IP54
Note: Any height adjustment must be done before
fastening the units or shipping splits together.
Height adjustment can be done by using metal
shims between the bottom frame and floor.
2
(2) Remove the lifting bars (if present). In marine
units, also replace the lifting lugs with L-profiles
(see below). Use the original bolts to block any
unused holes.
(3) If the line-up consists of shipping splits, fasten
the first split to the second. Each shipping split
includes a joining cubicle where the busbars
connect to the next split.
(4) Fasten the second shipping split to the floor.
(5) Join the DC busbars and the PE busbars.
(6) Repeat steps (2) to (5) for the remaining
3 shipping splits.
49
Fastening the cabinet to the floor (Non-marine units)

The cabinet is to be fastened to the floor by using clamps along the edge of the
cabinet bottom, or by bolting the cabinet to the floor through the holes inside.
Clamping
Insert the clamps into the twin slots along the front and rear edges of the cabinet
frame body and fasten them to the floor with a bolt. The recommended maximum
distance between the clamps is 800 mm (31.5”).
If there is not enough working space behind the cabinet for mounting, replace the
lifting lugs at the top with L-brackets (not included) and fasten the top of the cabinet
to the wall.
Slot detail, front view

(dimensions in millimetres)
Clamp dimensions (in millimetres) Distances between slots
Cubicle Distance in millimetres and (inches)

Width
(mm)
Cabinet frame
300 150 (5.9”)
400 250 (9.85”)
Cabinet frame 600 450 (17.7”)
700 550 (21.65”)
800 650 (25.6”)
L-bracket
M16 screw
Cabinet top
Fastening the cabinet at the top with

L-brackets (side view)
50
Holes inside the cabinet

The cabinet can be fastened to the floor using the fastening holes inside the cabinet,
if they are accessible. The recommended maximum distance between the fastening
points is 800 mm (31.5”).
If there is not enough working space behind the cabinet for mounting, replace the
lifting lugs at the top with L-brackets (not included) and fasten the top of the cabinet
to the wall.
Fastening holes inside the

cabinet (arrowed)
L-bracket
M16 screw
25 mm (0.985”)
Cabinet top

L-brackets (side view)
Distances between fastening holes Added width:

Bolt size: M10 to M12 (3/8” to 1/2”). Side panels of the cabinet: 15 mm (0.6”)
Back panel of the cabinet: 10 mm (0.4”)
Cubicle Distance between holes Gap between cubicles (mm):
Width Outer
Ø31 mm (1.22”) IP 20...42 IP 54
300 150 mm (5.9”)

400 250 (9.85”) ≈ 0.5 ≈1
(0.02”) (0.04”)
600 450 (17.7”)
700 550 (21.65”)
800 650 (25.6”)
51
Fastening the unit to the floor and wall (Marine units)

The unit must be fastened to the floor and roof (wall) as follows:
Bolt the unit to the floor through the holes in

1
each flat bar at the base of the cabinet using
M10 or M12 screws.
If there is not enough room behind the cabinet

2
for installation, clamp the rear ends of the flat
bars as shown in figure (2).
Fasten the top of the cabinet to the rear wall

3
and/or roof using brackets with a rubber
damper in between.
1
Use M10 or M12 screws; welding not

recommended (see section Electric
welding below).
2 3
Rubber damper
L-bracket
Back panel of M16 bolt

Clamps cabinet
Flat bars at base of cabinet Cabinet

Clamping the cabinet to the brackets and rubber dampers (side
floor at the back view)
52
Joining the shipping splits

The busbar systems and wiring harnesses of two shipping splits are joined in the
common motor terminal cubicle (if present) or a busbar joining cubicle. Special M6
screws for fastening the shipping splits together are enclosed in a plastic bag inside
the rightmost cubicle of the first shipping split. The threaded bushings are already
mounted on the post.
Threaded bushing
Procedure
Maximum tightening torque:

5 Nm (3 ft.-lbs)
7 7
• Fasten the front post of the joining section with 7 screws to the front frame post of
the next cubicle.
53
• Remove any intermediate or partitioning plates covering the rear posts of the
joining cubicle.
Partitioning
plate
Busbar joining Intermediate plate Back posts accessible

cubicle
• Fasten the rear post of the joining section with seven screws (below the busbar
joining part) to the rear post of the next cubicle.
• Replace all partitioning plates in the upper part of it after connecting the DC
busbars (see section Connecting the DC busbars and the PE busbar).
Connecting the DC busbars and the PE busbar

Horizontal main DC busbars and the PE busbar are connected from the front of the
joining cubicle. All necessary materials are located in the joining cubicle.
• Remove the front metal partitioning plate located in the busbar joining cubicle.
• Unscrew the bolts of the joint pieces.
• Connect the busbars with the joint pieces (see figure below). For aluminium
busbars, suitable anti-oxidant joint compound must be used to avoid corrosion
and to ensure good electrical connection. The oxide layer must be scrubbed off
from the joints before applying the compound.
• Refit all shrouds for safety of personnel.
54
DC busbars
The DC busbar connection is shown below.
1 1 Joint pieces
1
1
Tighten the bolts to

55–70 Nm (40–50 ft.-lbs.)
Side view of single busbar connection
PE busbar
The PE busbar runs continuously through the line-up near the floor at the back. The
connection is shown below. No separate nuts are needed.
Top view PE busbar
Tighten the screws to

55–70 Nm (40–50 ft.lbs.)
Shipping split A Shipping split B
55
Miscellaneous
Cable conduit in the floor below the cabinet

A cable conduit can be constructed below the 400 mm wide middle part of the
cabinet. The cabinet weight lies on the two 100 mm wide transverse sections which
the floor must carry.
Viewed from above Side view
With heavy
cabinets support
the structural C-
sections from
below.
This area can be used for a
cable conduit
Prevent the cooling air flow

from the cable conduit to
the cabinet by bottom
plates. To ensure the
degree of protection for the
cabinet use the original Cables
bottom plates delivered with
the unit. With user-defined
cable entries, take care of
the degree of protection, fire
protection and EMC
compliance.
56
Cooling air intake through bottom of cabinet

Units with air intake through the bottom of the cabinet (optional feature) are intended
for installation on an air duct in the floor. The required air inlets in the floor are as
listed below. Refer also to the dimensional drawings delivered with the unit.
• for DSU supply cubicles: w × 505 mm, where w equals cubicle width – 50 mm
• for ISU supply cubicles, inverter unit cubicles, control cubicles: w × 400 mm,
where w equals cubicle width – 50 mm
• w × 130 mm at the back of the cabinet line-up, where w equals the total width of
adjacent cubicles with air inlets. This area may or may not be consistent through
the width of the whole line-up.
Example
Input fuse cubicle Diode supply cubicle Inverter cubicle Common motor
Cubicle width: 400 mm Cubicle width: 700 mm Cubicle width: 600 mm terminal cubicle
Air inlet size: Air inlet size: Air inlet size: (No air inlet required)
350 × 400 mm 650 × 505 mm 550 × 400 mm
Notes:
• The plinth of the cabinet must be supported all round.
• The air duct must be able to supply a sufficient volume of cooling air. The
minimum air flow values are given in the Technical data section of the Hardware
Manual.
• The cubicles of diode supply units require a larger air inlet area than other
cubicles.
• Some cubicles (mainly those without active, heat-generating components) require
no air inlet.
57
Electric welding
It is not recommended to fasten the cabinet by welding.
Cabinets without flat bars at the base
• Connect the return conductor of the welding equipment to the cabinet frame at
the bottom within 0.5 metres of the welding point.
Cabinets with flat bars at the base
• Weld only the flat bar under the cabinet, never the cabinet frame itself.
• Clamp the welding electrode onto the flat bar about to be welded or onto the floor
within 0.5 metres of the welding point.
WARNING! If the welding return wire is connected improperly, the welding circuit
may damage electronic circuits in the cabinet. The thickness of the zinc coating of
the cabinet frame is 100 to 200 micrometres; on the flat bars the coating is
approximately 20 micrometres. Ensure that the welding fumes are not inhaled.
58
59

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

1. Select the motor according to the rating tables in chapter Technical Data. Use
DriveSize PC tool if the default load cycles are not applicable.
2. Check that the motor ratings lie within the allowed ranges of the drive control
program:
• motor nominal voltage is 1/2 ... 2 · UN of the drive
• motor nominal current is 1/6 ... 2 · I2hd of the drive in DTC control and
0 ... 2 · I2hd in scalar control. The control mode is selected by a drive parameter.

60
3. Check that the motor voltage rating meets the application requirements:
If the drive is equipped with … … and … … then the motor voltage
rating should be …
diode supply no resistor braking is used UN

(ACS800-01, ACS800-U1,
frequent or long-term brake cycles UACeq1
ACS800-02, ACS800-U2,
are used
ACS800-04, ACS800-04M,
ACS800-U4, ACS800-07,
ACS800-U7)
IGBT supply DC link voltage is not increased from UN

(ACS800-11, ACS800-U11, nominal (through parameter settings)
ACS800-17, ACS800-37)
DC link voltage is increased from UACeq2
nominal (through parameter settings)
U N = Rated input voltage of drive

U ACeq1 = UDC / 1.35
U ACeq2 = UDC / 1.41
U ACeq = Equivalent AC power source voltage of drive in V AC
U DC = Maximum DC link voltage of drive in V DC. For resistor braking, UDC = 1.21 × nominal DC link
voltage. For units with IGBT supply: see the parameter value. Note: Nominal DC link voltage is UN × 1.35 or
U N × 1.41 in V DC.
See notes 6 and 7 below the Requirements table.

4. Consult the motor manufacturer before using a motor in a drive system where the
motor nominal voltage differs from the AC power source voltage.
5. Ensure that the motor insulation system withstands the maximum peak voltage in
the motor terminals. See the Requirements table below for the required motor
insulation system and drive filtering.
Example 1: When the supply voltage is 440 V and the drive has a diode supply
and operates in motor mode only, the maximum peak voltage at the motor
terminals can be approximated as follows: 440 V × 1.35 × 2 = 1190 V. Check that
the motor insulation system withstands this voltage.
Example 2: When the supply voltage is 440 V and the drive is equipped with an
IGBT supply, the maximum peak voltage in the motor terminals can be
approximated as follows: 440 V × 1.41 × 2 = 1241 V. Check that the motor
insulation system withstands this voltage.
Protecting the motor insulation and bearings

The output of the drive comprises – regardless of output frequency – pulses of
approximately 1.35 times the equivalent mains network voltage with a very short rise
time. This is the case with all drives employing modern IGBT inverter technology.
The voltage of the pulses can be almost double at the motor terminals, depending on
the attenuation and reflection properties of the motor cable and the terminals. This in
turn can cause additional stress on the motor and motor cable insulation.
Modern variable speed drives with their fast rising voltage pulses and high switching
frequencies can cause current pulses that flow through the motor bearings, which
can gradually erode the bearing races and rolling elements.

61
The stress on motor insulation can be avoided by using optional ABB du/dt filters.
du/dt filters also reduce bearing currents.
To avoid damage to motor bearings, the cables must be selected and installed
according to the instructions given in this manual. In addition, insulated N-end (non-
driven end) bearings and output filters from ABB must be used according to the
following table. Two types of filters are used individually or in combinations:
• du/dt filtering (protects motor insulation system and reduces bearing currents).
• common mode filtering (CMF) (mainly reduces bearing currents).
Requirements table
The following table shows how to select the motor insulation system and when an
optional ABB du/dt filter, insulated N-end (non-driven end) motor bearings and ABB
common mode filters are required. The motor manufacturer should be consulted
regarding the construction of the motor insulation and additional requirements for
explosion-safe (EX) motors. Failure of the motor to fulfil the following requirements
or improper installation may shorten motor life or damage the motor bearings.
Motor type Nominal mains Requirement for
voltage (AC line Motor insulation ABB du/dt filter, insulated N-end bearing and ABB common mode
voltage)
Manufacturer
system filter
PN < 100 kW 100 kW < PN < 350 kW PN > 350 kW
and or or
frame size < IEC 315 frame size > IEC 315 frame size > IEC 400
PN < 134 HP 134 HP < PN < 469 HP PN > 469 HP
and frame size or frame size or frame size
< NEMA 500 > NEMA 500 > NEMA 580
A Random- UN < 500 V Standard - +N + N + CMF
B wound M2_
500 V < UN < 600 V Standard + du/dt + du/dt + N + du/dt + N + CMF
and M3_
B or
Reinforced - +N + N + CMF
600 V < UN < 690 V Reinforced + du/dt + du/dt + N + du/dt + N + CMF
Form-wound 380 V < UN < 690 V Standard n.a. + N + CMF PN < 500 kW:
HX_ and AM_ + N + CMF
PN > 500 kW:
+ N + CMF + du/dt
Old* form- 380 V < UN < 690 V Check with the + du/dt with voltages over 500 V + N + CMF
wound HX_ motor
and modular manufacturer.
Random- 0 V < UN < 500 V Enamelled wire + N + CMF
wound HX_ with fibre glass
500 V < UN < 690 V + du/dt + N + CMF
and AM_ ** taping

62

voltage (AC line
Motor insulation ABB du/dt filter, insulated N-end bearing and ABB common mode
voltage)
Manufacturer
system filter
PN < 100 kW 100 kW < PN < 350 kW PN > 350 kW
and or or
frame size < IEC 315 frame size > IEC 315 frame size > IEC 400
PN < 134 HP 134 HP < PN < 469 HP PN > 469 HP
and frame size or frame size or frame size
< NEMA 500 > NEMA 500 > NEMA 580
N Random- UN < 420 V Standard: ÛLL = - + N or CMF + N + CMF
O wound and 1300 V
form-wound
N 420 V < UN < 500 V Standard: ÛLL = + du/dt + du/dt + N + du/dt + N + CMF
- 1300 V or
A
+ du/dt + CMF
B
or
B
Reinforced: ÛLL = - + N or CMF + N + CMF
1600 V, 0.2 µs
rise time
500 V < UN < 600 V Reinforced: Û LL = + du/dt + du/dt + N + du/dt + N + CMF
1600 V
or
+ du/dt + CMF
or
Reinforced: ÛLL = - + N or CMF + N + CMF
1800 V
600 V < UN < 690 V Reinforced: ÛLL = + du/dt + du/dt + N + du/dt + N + CMF
1800 V
Reinforced: ÛLL = - N + CMF N + CMF
2000 V, 0.3 µs
rise time ***
* manufactured before 1.1.1998

** For motors manufactured before 1.1.1998, check for additional instructions with the motor manufacturer.
*** If the intermediate DC circuit voltage of the drive will be increased from the nominal level by resistor braking or
by the IGBT supply unit control program (parameter selectable function), check with the motor manufacturer if
additional output filters are needed in the applied drive operation range.
Note 1: The abbreviations used in the table are defined below.
Abbreviation Definition
UN nominal voltage of the supply network
ÛLL peak line-to-line voltage at motor terminals which the motor insulation must withstand
PN motor nominal power
du/dt du/dt filtering at the output of the drive (+E205)
CMF common mode filtering (+E208)
N N-end bearing: insulated motor non-driven end bearing
n.a. Motors of this power range are not available as standard units. Consult the motor manufacturer.
Note 2: Explosion-safe (EX) motors

The motor manufacturer should be consulted regarding the construction of the motor insulation and
additional requirements for explosion-safe (EX) motors.
Note 3: High-output motors and IP 23 motors
For motors with higher rated output than what is stated for the particular frame size in EN 50347 (2001)
and for IP 23 motors, the requirements of ABB random-wound motor series M3AA, M3AP, M3BP are

63
given below. For other motor types, see the Requirements table above. Apply the requirements of
range “100 kW < P N < 350 kW” to motors with PN < 100 kW. Apply the requirements of range PN >
350 kW to motors within the range “100 kW < PN < 350 kW”. In other cases, consult the motor
manufacturer.
Manufacturer

voltage (AC line
Motor insulation ABB du/dt filter, insulated N-end bearing and ABB common mode
voltage) system filter
PN < 55 kW 55 kW < PN < 200 kW PN > 200 kW
PN < 74 HP 74 HP < PN < 268 HP PN > 268 HP
A Random- UN < 500 V Standard - +N + N + CMF

B wound M3AA, 500 V < UN < 600 V Standard + du/dt + du/dt + N + du/dt + N + CMF
M3AP, M3BP
B
or
Reinforced - +N + N + CMF
600 V < UN < 690 V Reinforced + du/dt + du/dt + N + du/dt + N + CMF
Note 4: HXR and AMA motors

All AMA machines (manufactured in Helsinki) for drive systems have form-wound windings. All HXR
machines manufactured in Helsinki starting 1.1.1998 have form-wound windings.
Note 5: ABB motors of types other than M2_, M3_, HX_ and AM_
Use the selection criteria given for non-ABB motors.
Note 6: Resistor braking of the drive
When the drive is in braking mode for a large part of its operation time, the intermediate circuit DC
voltage of the drive increases, the effect being similar to increasing the supply voltage by up to 20
percent. The voltage increase should be taken into consideration when determining the motor insulation
requirement.
Example: Motor insulation requirement for a 400 V application must be selected as if the drive were
supplied with 480 V.
Note 7: Drives with an IGBT supply unit
If voltage is raised by the drive (this is a parameter selectable function for special applications only),
select the motor insulation system according to the increased intermediate circuit DC voltage level,
especially in the 500 V supply voltage range.
Note 8: Calculating the rise time and the peak line-to-line voltage
The peak line-to-line voltage at the motor terminals generated by the drive as well as the voltage rise
time depend on the cable length. The requirements for the motor insulation system given in the table
are “worst case” requirements covering installations with 30-metre and longer cables. The rise time can
be calculated as follows: t = 0.8 · ÛLL/(du/dt). Read ÛLL and du/dt from the diagrams below. Multiply
the values of the graph by the supply voltage (UN). In case of drives with an IGBT supply unit or resistor
braking, the ÛLL and du/dt values are approximately 20% higher.

64
3.0 5.5
Û LL/UN 5.0
2.5 du/dt
------------- (1/µs)
4.5 UN
2.0 4.0
3.5
1.5
3.0
ÛLL/UN
1.0 2.5
du/dt
------------- (1/µs)
UN 2.0
0.5
1.5
0.0 1.0
100 200 300 100 200 300
Cable length (m) Cable length (m)
With du/dt Filter Without du/dt Filter
Note 9: Sine filters

Sine filters protect the motor insulation system. Therefore, a du/dt filter can be replaced with a sine
filter. The peak phase-to-phase voltage with a sine filter is approximately 1.5 × UN.
Permanent magnet synchronous motor

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

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

switch or a circuit breaker must be used for protecting each cable and motor. These
devices may require a separate fuse to cut off the short-circuit current.
The drive protects the motor cable and the motor in a short-circuit situation when the
motor cable is dimensioned according to the nominal current of the drive.

65
Supply (AC line) cable short-circuit protection

Always protect the input cable with fuses. In networks with a short-circuit withstand
of 65 kA or less, standard gG fuses can be used. No fuses need be installed at the
drive input.
If the drive is supplied through busbars, fuses must be installed at the drive input. In
networks with a short-circuit withstand of less than 50 kA, standard gG fuses are
sufficient. If the network has a short-circuit withstand of 50…65 kA, aR fuses are
required.
Size the fuses according to local safety regulations, appropriate input voltage and
the rated current of the drive. Check that the operating time of the fuses is below
0.5 seconds. For fuse ratings, see Technical Data.
WARNING! Circuit breakers are not capable of providing sufficient protection

because they are inherently slower than fuses. Always use fuses with circuit
breakers.
Earth fault (Ground fault) protection

Both the supply unit and the inverter unit are equipped with an internal earth fault
protective function to protect the drive against earth faults in the drive, motor and
motor cable. (This is not a personal safety or a fire protection feature.) Both earth
fault protective functions can be disabled.
See the ACS800 Ordering Information (code: 64556568 [English], available on
request) for other available earth fault protection options.
The EMC filter (if present) includes capacitors connected between the main circuit
and the frame. These capacitors and long motor cables increase the earth leakage
current and may cause fault current circuit breakers to function.
Emergency stop devices

For safety reasons, install the emergency stop devices at each operator control
station and at other operating stations where emergency stop may be needed.
Pressing the stop key ( ) on the control panel of the drive, or turning the operating
switch of the drive from position “1” to “0” does not generate an emergency stop of
the motor or separate the drive from dangerous potential.
An emergency stop function is optionally available for stopping and switching off the
whole drive. Two modes are available: immediate removal of power (Category 0)
and controlled emergency stop (Category 1).
Restarting after an emergency stop

After an emergency stop, the emergency stop button must be released and a reset
performed before the main contactor (or air circuit breaker) can be closed and the
drive started.

66
Prevention of unexpected start

The drive can be equipped with an optional prevention of unexpected start function
according to standards IEC/EN 60204-1: 1997; ISO/DIS 14118: 1996 and EN 1037:
1996. The circuit conforms to EN954-1, Category 3.
The function is achieved by disconnecting the control voltage to the power
semiconductors of the inverters of the drive. Thus it is not possible for the power
semiconductors to switch and generate the AC voltage needed to rotate the motor.
In case of faulty main circuit components, the DC voltage from the busbars can be
conducted to the motor but an AC motor cannot rotate without the field generated by
an AC voltage.
The operator activates the prevention of unexpected start function using a switch
mounted on a control desk. When the function is activated, the switch is opened, and
an indicator lamp will light.
WARNING! The prevention of unexpected start function does not disconnect the
voltage of the main and auxiliary circuits from the drive. Therefore maintenance work
on electrical parts of the drive can only be carried out after isolating the drive system
from the main supply.
Note: The prevention of unexpected start function is not intended for stopping the
drive. If a running drive is stopped by using the prevention of unexpected start
function, the drive will cut off the motor supply voltage and the motor will coast to
stop.

67
Selecting the power cables
General rules
Dimension the supply (input power) and motor cables according to local
regulations:
• The cable must be able to carry the drive load current. See chapter Technical
data for the rated currents.
• The cable must be rated for at least 70 °C maximum permissible temperature of
conductor in continuous use. For US, see Additional US requirements.
• The inductance and impedance of the PE conductor/cable (grounding wire) must
be rated according to permissible touch voltage appearing under fault conditions
(so that the fault point voltage will not rise excessively when an ground fault
occurs).
• 600 VAC cable is accepted for up to 500 VAC. For 690 VAC rated equipment, the
rated voltage between the conductors of the cable should be minimum 1 kV.
For drive frame size R5 and larger, or motors larger than 30 kW, symmetrical
shielded motor cable must be used (figure below). A four-conductor system can be
used up to frame size R4 with up to 30 kW motors, but shielded symmetrical motor
cable is recommended.
Note: When continuous conduit is employed, shielded cable is not required.
A four-conductor system is allowed for input cabling, but shielded symmetrical cable
is recommended. To operate as a protective conductor, the shield conductivity must
be as follows when the protective conductor is made of the same metal as the phase
conductors:
Cross-sectional area of the phase Minimum cross-sectional area of the
conductors corresponding protective conductor
S (mm2) Sp (mm 2)
S < 16 S
16 < S < 35 16
35 < S S/2
Compared to a four-conductor system, the use of symmetrical shielded cable

reduces electromagnetic emission of the whole drive system as well as motor
bearing currents and wear.
Note: The cabinet configuration of the drive may require multiple supply and/or
motor cabling. Refer to the connection diagrams in Electrical installation.
The motor cable and its PE pigtail (twisted screen) should be kept as short as
possible in order to reduce electromagnetic emission as well as capacitive current.

68
Alternative power cable types

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

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

Insulation jacket
Cable core

69
Additional US requirements
Type MC continuous corrugated aluminum armor cable with symmetrical grounds or
shielded power cable must be used for the motor cables if metallic conduit is not
used. For the North American market, 600 VAC cable is accepted for up to 500 VAC.
1000 VAC cable is required above 500 VAC (below 600 VAC). For drives rated over
100 amperes, the power cables must be rated for 75 °C (167 °F).
Conduit
Where conduits must be coupled together, bridge the joint with a ground conductor
bonded to the conduit on each side of the joint. Bond the conduits also to the drive
enclosure. Use separate conduits for input power, motor, brake resistors, and control
wiring. When conduit is employed, type MC continuous corrugated aluminum armor
cable or shielded cable is not required. A dedicated ground cable is always required.
Note: Do not run motor wiring from more than one drive in the same conduit.
Armored cable / shielded power cable

6-conductor (3 phases and 3 ground) type MC continuous corrugated aluminum
armor cable with symmetrical grounds is available from the following suppliers (trade
names in parentheses):
• Anixter Wire & Cable (Philsheath)
• BICC General Corp (Philsheath)
• Rockbestos Co. (Gardex)
• Oaknite (CLX).
Shielded power cables are available from Belden, LAPPKABEL (ÖLFLEX) and
Pirelli, among others.

70
Power factor compensation capacitors

Power factor compensation is not needed with AC drives. However, if a drive is to be
connected in a system with compensation capacitors installed, note the following
restrictions.
WARNING! Do not connect power factor compensation capacitors to the motor

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

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

71
Before opening an output contactor (in DTC motor control mode)

Stop the drive and wait for the motor to stop before opening a contactor between the
output of the drive and the motor when the DTC control mode is selected. (See the
Firmware Manual of the drive for the required parameter settings.) Otherwise, the
contactor will be damaged.
In scalar control, the contactor can be opened with the drive running.
Relay output contacts and inductive loads

Inductive loads (such as relays, contactors, motors) cause voltage transients when
switched off.
The relay contacts of the RMIO board are protected with varistors (250 V) against
overvoltage peaks. In spite of this, it is highly recommended to equip inductive loads
with noise attenuating circuits (varistors, RC filters [AC] or diodes [DC]) in order to
minimize the EMC emission at switch-off. If not suppressed, the disturbances may
connect capacitively or inductively to other conductors in the control cable and form
a risk of malfunction in other parts of the system.
Install the protective component as close to the inductive load as possible. Do not
install the protective components at the terminal block.
Relay outputs
Varistor
RO (NC)
RO (C)
230 VAC
RO (NO)
RC filter
RO (NC)
230 VAC RO (C)
RO (NO)
Diode
RO (NC)
24 VDC RO (C)
RO (NO)

72
Selecting the control cables

All control cables must be shielded.
Use a double-shielded twisted pair cable (see figure a) for analogue signals. This
type of cable is recommended for the pulse encoder signals also. Employ one
individually shielded pair for each signal. Do not use common return for different
analogue signals.
A double-shielded cable is the best alternative for low-voltage digital signals but
single-shielded twisted multipair cable (figure b) is also usable.
a b
Double-shielded twisted Single-shielded twisted
pair cable multipair cable
Run analogue and digital signals in separate, shielded cables.

Relay-controlled signals, providing their voltage does not exceed 48 V, can be run in
the same cables as digital input signals. It is recommended that the relay-controlled
signals be run as twisted pairs.
Never mix 24 VDC and 115 / 230 VAC signals in the same cable.
Relay cable
The cable type with braided metallic screen (e.g. ÖLFLEX LAPPKABEL, Germany)
has been tested and approved by ABB.
Control panel cable

In remote use, the cable connecting the control panel to the drive must not exceed 3
metres (10 ft). The cable type tested and approved by ABB is used in control panel
option kits.
Coaxial cable (for use with Advant Controllers AC 80/AC 800)

• 75 ohm
• RG59, diameter 7 mm or RG11, diameter 11 mm
• Maximum cable length: 300 m (1000 ft)

73
Connection of a motor temperature sensor to the drive I/O
WARNING! IEC 60664 requires double or reinforced insulation between live parts
and the surface of accessible parts of electrical equipment which are either non-
conductive or conductive but not connected to the protective earth.
To fulfil this requirement, the connection of a thermistor (and other similar
components) to the digital inputs of the drive can be implemented in three alternate
ways:
1. There is double or reinforced insulation between the thermistor and live parts of
the motor.
2. Circuits connected to all digital and analogue inputs of the drive are protected
against contact and insulated with basic insulation (the same voltage level as the
drive main circuit) from other low voltage circuits.
3. An external thermistor relay is used. The insulation of the relay must be rated for
the same voltage level as the main circuit of the drive. For connection, see the
Firmware Manual.
Installation sites above 2000 metres (6562 feet)
WARNING! Wear appropriate protection when installing, operating or servicing the

RMIO board wiring and optional modules attached to the board. The Protective Extra
Low Voltage (PELV) requirements stated in EN 50178 are not fulfilled at altitudes
above 2000 m (6562 ft).
Routing the cables

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

74
A diagram of the cable routing is below.
Motor cable
Drive
min 300 mm (12 in.)
Power cable
Input power cable Motor cable
min 200 mm (8 in.) 90 °

min 500 mm (20 in.)
Control cables
Control cable ducts

24 V 230/120 V 24 V 230/120 V
Not allowed unless the 24 V cable is Lead 24 V and 230/120 V control

insulated for 230 V (120 V) or cables in separate ducts into the
insulated with an insulation sleeving inside of the cabinet.
for 230 V (120 V).

75

This chapter describes the electrical installation procedure of the drive.
WARNING! Only qualified electricians are allowed to carry out the work described in
this chapter. Follow the Safety instructions on the first pages of this manual. Ignoring
the safety instructions can cause injury or death.
WARNING! During the installation procedure, inverter modules may have to be

temporarily extracted from the cabinet. The modules have a high centre of gravity. In
order to minimise the danger of toppling over, keep the support legs (if provided) of
the modules extended whenever manoeuvring the modules outside the cabinet.
Option coding
Some instructions contained within this chapter are intended for drives equipped
with certain options, marked with “plus codes” (e.g. +H359). The options included in
a drive are listed on its type code label. An option code listing is included in this
manual on page 39.
76
Before installation
Checking the insulation of the assembly

Every drive has been tested for insulation between the main circuit and the chassis
(2500 V rms 50 Hz for 1 second) at the factory. Therefore, do not make any voltage
tolerance or insulation resistance tests (e.g. hi-pot or megger) on any part of the
drive. When checking the insulation of the assembly, proceed in the following
manner:
WARNING! Check the insulation before connecting the drive to the supply. Make
sure that the drive is disconnected from the supply (input power).
1. Check that all motor cables are disconnected from the drive output terminals.
2. Measure the insulation resistances of the motor cable and the motor between
each phase and the Protective Earth by using a measuring voltage of 1 kV DC.
The insulation resistance must be higher than 1 Mohm.
M
ohm
PE
IT (ungrounded) systems
EMC filter +E202 is not suitable for use in an IT (ungrounded) system. If the drive is
equipped with EMC filter +E202, disconnect the filter before connecting the drive to
the supply network. For detailed instructions on how to do this, please contact your
local ABB representative.
WARNING! If a drive with EMC filter +E202 is installed on an IT system [an

ungrounded power system or a high resistance-grounded (over 30 ohms) power
system], the system will be connected to earth potential through the EMC filter
capacitors of the drive. This may cause danger, or damage the unit.
77
Input power connection – Frame R6
Connection diagram
Q1 K1 U1
L1
L2
L3
PE
Connection procedure
Note: Before making the cable connections, check that the input of the auxiliary
voltage transformer (T10) is selected correctly according to the supply voltage.
1. Open the door of the cabinet.
2. Remove any shrouds that protect the input busbars and cable entries.
3. Lead the cables into the inside of the cubicle. It is recommended to apply 360°
grounding of the cable shields at the entry as shown below.
4. Connect the cables as follows:

• Twist the cable shields into bundles and connect to cabinet PE (ground) busbar.
Connect any separate ground conductors or cables to cabinet PE (ground)
busbar.
• Connect the phase conductors to the input power terminals (L1, L2, L3). For the
tightening torques, see the chapter Technical data.
5. Provide support for the cables whenever necessary.
6. Refit all shrouds removed earlier and close the door.
78
Input power connection – Frame R7i
Connection diagram
Q1 K1 L1 U1
L1
L2
L3
PE
Note: Before making the cable connections, check that the input of the auxiliary
voltage transformer (T10) is selected correctly according to the supply voltage.
1. Open the door of the cabinet.

busbar.
79
Input power connection – Frame size R8i
Connection diagram
Q1 K1 L1 U1
L1
L2
L3
PE
Note: Before making the cable connections, check that the tap settings of the
auxiliary voltage transformer (T10, located in the input/output cubicle) are correct in
regard to the supply voltage. See instructions on page 94.
1. Open the door of the input/output cubicle (see section Cabling direction starting on
page 29).

busbar.
80
Input power connection – Frame size 2×R8i and up
Connection diagram
U<
Q1
L1
L2
L3
PE
1. Open the door of the incoming cubicle (see section Cabling direction starting on
page 29).

busbar.
81
Motor connection – Frame R6
Connection diagram
PE
U2
V2
U1
V1
M
W2
W1 3~
PE
1. Open the cabinet door.
2. Remove any shrouds that protect the output busbars and cable entries.

busbar.
• Connect the phase conductors to the output power terminals (U2, V2, W2). For
the tightening torques, see the chapter Technical data.
82
Motor connection – Frame R7i
Connection diagram
PE
U2
V2
U1
V1
M
W2
W1 3~
PE
1. Open the cabinet door.

busbar.
83
Motor connection – Frame R8i units without option +E202 or +H359
Connection diagram
PE
U2
V2
U1
V1
M
W2
W1 3~
PE
Supply and inverter unit cubicle Input/output cubicle
Note: Before making the cable connections, consider checking the tap settings of
the auxiliary voltage transformer located in the input/output cubicle. See instructions
on page 94.
1. Open the door of the input/output cubicle (see section Cabling direction starting on
page 29).

busbar.
84
Motor connection – Frame R8i with option +E202 but without +H359
Output busbars
The motor cables are to be connected to the output busbars behind the inverter
module. For the location and dimensions of the busbars, see the chapter
Dimensions.
Connection diagram
PE
U2
V2
U1
V1
M
W2
W1 3~
PE
Inverter unit cubicle
WARNING! The inverter module is heavy and has a high centre of gravity. Be careful when
manoeuvring the module. In order to minimise the danger of toppling over, keep the support legs
of the module extended whenever manoeuvring it outside the cabinet.
Extract the inverter module from the cubicle as follows (refer to the pictures below):
1. Open the door of the supply and inverter unit cubicle (see section Cabling direction starting on page 29).
2. Remove any shrouds that protect the busbars and cable entries.
3. Open the transparent cover on the front of the inverter module (the rightmost module) and disconnect
the fibre optic cables. Move the cables aside.
4. Remove the L-shaped DC busbars on top of the inverter module.
5. Disconnect the terminal block (X50) 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; lift 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.
85
6a
4 8
3
6c
9a 9b
6b
86
Lead the cables into the cabinet at the inverter module. Make the 360° earthing arrangement at the cable
entry as shown.
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 (U2, V2, W2).
Use the tightening torques specified in the chapter Technical data.
Provide support for the cables whenever necessary.
Insert the 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, 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.
87
Motor connection – Units with common motor terminal cubicle (+H359)
Connection diagram
PE
U2
V2
U1
V1
M
W2
W1 3~
PE
Inverter unit cubicle(s) Common motor terminal

cubicle
1. Open the door of the common motor terminal cubicle (see section Cabling
direction starting on page 29).

busbar.
88
Motor connection – Frame 2×R8i and up without common motor terminal

cubicle
Output busbars
The motor cables are to be connected to the output busbars behind each inverter
module. For the location and dimensions of the busbars, see the chapter
Dimensions.
Connection diagram
PE
U2
V2
W2
U1
V1
M
W1 3~
U2 PE
V2
W2
Inverter unit cubicle(s)
WARNING! The cabling from all inverter modules to the motor must be physically
identical considering cable type, cross-sectional area, and length.
PE
U2
V2
W2
U1
V1
M
W1 3~
U2 PE
V2
W2
Inverter unit cubicle
89
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 (refer to the pictures below):
1. Open the door of the inverter unit cubicle (see section Cabling direction starting on page 29).
2. Remove any shrouds that protect the busbars and cable entries.
3. Open the transparent cover on the front of the inverter module (the rightmost module) and disconnect
the fibre optic cables. Move the cables aside.
4. Remove the L-shaped DC busbars on top of the inverter module.
5. Disconnect the terminal block (X50) 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; lift 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 8
3
6c
9a 9b
6b
90
Lead the cables into the cabinet at the inverter module. Make the 360° earthing arrangement at the cable
entry as shown.
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 (U2, V2, W2).
Use the tightening torques specified in the chapter Technical data.
Provide support for the cables whenever necessary.
Insert the 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, 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 cubicle door.
91
Control connections
Drive control connections

The control connections are made on the terminal blocks provided in the swing-out
frame of the drive. Refer to the circuit diagrams delivered with the drive, and to the
chapter Motor control and I/O board (RMIO).
Supply unit control connections
The supply unit is controlled using the local control devices optionally mounted on
the cabinet door, i.e. the start switch, reset button and emergency stop button. No
additional control connections are used or needed. However, it is also possible to
• halt the supply unit by an external emergency stop button (if the unit is equipped
with a local emergency stop button, external buttons can be connected in series)
• read a fault indication through a relay output
• communicate with the unit through a serial communication interface.
Refer to the circuit diagrams delivered with the drive for the connection terminals for
the external control devices.
Open the cabinet door(s).
Remove the locking screws at the edge of the swing-out frame and open the frame.
Remove any shrouds that limit access to the cable lead-throughs and cable 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.
92
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 appropriate terminals. Wherever possible, use the existing cable trunking in the
cabinet. Use sleeving wherever the cables are laid against sharp edges. When running cables to the
swing-out frame, leave some slack in the cable at the hinge to allow the frame to open fully. Tie the cables
to the cable supports wherever necessary.
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.
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 shrouds removed earlier. Close the swing-out frame, refasten, and close the cabinet door(s).
93
Installation of optional modules and PC

Optional modules (such as fieldbus adapters, I/O extension modules and pulse
encoder interfaces) are inserted into the optional module slot of the RMIO boards
(built in the RDCU drive control units) and secured with two screws. The slots on the
RMIO boards are described on page 35. See the appropriate optional module
manual for information on the cable connections.
Cabling of I/O and fieldbus modules
Module
Keep unshielded portion as
short as possible
Shield
1
2
3
4
To nearest PE terminal
Cabling of pulse encoder interface module
CHASSIS
RTAC-01
PULSE ENCODER INTERFACE
GND
Note 1: If the encoder is of unisolated
12345678 123456
SHLD
F01
type, ground the encoder cable at the
DE
23
SHLD
C
456
AB
789
CHA
CHA+
CHA-
X2
CHB
WD/
drive end only. If the encoder is
Keep unshielded portion as CHB+
CHB-
INIT
galvanically isolated from the motor
NODE ID
short as possible CHZ+
CHZ-
shaft and the stator frame, ground the
0V
0V
encoder cable shield at the drive and
the encoder end.
1
2
3
4
VOUT
+15V
X1
VIN
+24V
Note 2: Twist the pair cable wires.
Fibre optic links

DDCS fibre optic links are provided by RDCO modules (optionally installed on the
RDCU control units) for PC tools, master/follower link, NDIO, NTAC, NAIO, AIMA I/O
module adapter and fieldbus adapter modules of type Nxxx. See the RDCO User’s
Manual [3AFE 64492209 (English)] 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.
94
Tap settings of the auxiliary voltage transformer (Frame R8i and up)
3~ Input
Primary
Secondary
Output
3~ input 1~ output 3~ output
Supply Tap settings Supply 230 V 115 V 400 V (50 Hz) 320 V (60 Hz)
Terminals
voltage A1 to... B1 to… C1 to… voltage Terminals Tap setting Terminals Tap setting Terminals Terminals
690 V A1, B1, C1 C2 A2 B2 690 V a3, n1 230– a4, n1 115– a1, b1, c1 a2, b2, c2
660 V A1, B1, C1 C2 A2 B2 660 V a3, n1 230+ a4, n1 115+ a1, b1, c1 a2, b2, c2
Installation of brake resistors

See the chapter Resistor braking.
95

This chapter shows
• external control connections to the RMIO board for the the ACS 800 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-01 board (revision J
or later) or the RMIO-02 board (revision H or later).
Note on cabinet-installed 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 terminal labelling

Optional modules (type Rxxx) may have terminal designations that coincide with
those on the RMIO board.

96
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

97
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

98
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

99
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, and that the installation site is below 2000 m (6562 ft) in altitude. For installation at higher altitudes,
see page 73.

100
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

101

This chapter contains an installation checklist, a start-up procedure for the drive, and
listings of parameters specific to the ACS800-37.
Installation checklist
Check the mechanical and electrical installation of the drive before start-up. Go
through the checklist below together with another person.
WARNING! Only qualified electricians are allowed to commission the drive. Read
and follow the Safety instructions on the first pages of this manual. Neglecting the
safety instructions can cause injury or death.
Check…
MECHANICAL INSTALLATION
The ambient operating conditions are allowed. See Electrical installation, Technical data: IEC ratings or Ambient
conditions.
The unit is fixed properly to floor. See Mechanical installation.
The cooling air will flow freely.
ELECTRICAL INSTALLATION See Planning the electrical installation, Electrical installation.
The motor and the driven equipment are ready for start.
The EMC filter (option +E202) is disconnected if the drive is connected to an IT (ungrounded) system.
The drive is grounded properly.
The supply (input power) voltage matches the nominal input voltage of the drive.
The supply (input power) connection to the input terminals are OK.
Appropriate supply (input power) fuses and disconnector are installed.
The motor connections at the output terminals are OK.
The motor cable is routed away from other cables.
Settings of the auxiliary voltage transformer.
There are no power factor compensation capacitors in the motor cable.
The external control connections inside the drive are OK.
There are no tools, foreign objects or dust from drilling inside the drive.
Supply (input power) voltage cannot be applied to the output of the drive (with a bypass connection).

102
Check…
For drives with Category 1 Emergency stop function: The time relay has been set to a suitable value (e.g.
somewhat longer than the stop ramp of the inverter units).
All shrouds are in place.
Start-up procedure
WARNING! Ensure that the disconnector of the supply transformer is
locked to open position, i.e. no voltage is, or cannot be connected to
drive inadvertently. Check also by measuring that there is no voltage
connected.
Basic checks with no voltage connected
If the unit is equipped with an air circuit breaker, check the current trip Optional device. See the delivery-
limits of the breaker (preset at the factory). specific circuit diagrams.
General rule
Ensure the selectivity condition is fulfilled i.e. the breaker trips at a lower
current than the protection device of the supplying network, and that the
limit is high enough not to cause unnecessary trips during the
intermediate DC circuit load peak at start.
Long-term current limit
As a rule of thumb, this should be set to the rated AC current of the
module.
Peak current limit
As a rule of thumb, this should be set to a value 3-4 times the rated AC
current of the module.
Check the settings of the relays and breakers/switches of the auxiliary Optional devices. See delivery
circuits. specific circuit diagrams.
Disconnect any unfinished or unchecked 230/115 VAC cables that lead
from the terminal blocks to the outside of the equipment.
For drive types ACS800-37-0640-3/0780-5/0790-7 and up: Locate the These drive types have two PPCS
APBU-xx PPCS branching units. Enable memory backup battery on branching units, one for the supply
each branching unit by setting actuator 6 of switch S3 to ON. unit, one for the inverter unit. By
default, memory backup is switched
off to save the battery.
Connecting voltage to input terminals and auxiliary circuit
WARNING! When voltage is connected to the input terminals, voltage
may also be connected to the auxiliary circuits of the drive.
Make sure that it is safe to apply voltage. Ensure that:
• nobody is working on the unit or circuits that are wired from outside into
the cabinets
• cabinet doors are closed
• covers of motor terminal boxes are in place.
Open the earthing/grounding switch (Q9) if present. The earthing/grounding switch and
the main disconnecting device are
either mechanically or electrically
interlocked so that the earthing/
grounding switch can only be closed
when the main disconnecting switch
is open, and vice versa.
Close the main breaker of the supply transformer.

103

Close the auxiliary circuit On/Off switch (Q100) if present.
Starting the supply unit
Close the main switch/disconnector (Q1).
Units with emergency stop: Turn the Start switch on the cabinet door
from 0 into START position for 2 seconds, then release the switch and
leave it in position 1.
Checks with the supply unit running
Check the settings of the earth fault (ground fault) monitoring device (if See chapter Electrical installation.
present).
Supply (line-side converter) program set-up
Parameters of the IGBT supply unit need not be set during the start-up
procedure, or in normal use. In case the parameters of the supply unit
need to be changed, switch the control panel (optional) to view the line-
side converter as described in section Control panel on page 37.
Alternatively, a PC equipped with a programming tool (e.g.
DriveWindow) can be connected to channel CH3 of the inverter unit’s
RDCU.
Note: It is recommended to set parameter 16.15 I/O START MODE to
DI2 LEVEL if
• the motor is started and stopped frequently. This prolongs the life of
the charging contactor,
• the drive is equipped with the emergency stop option,
• when it is required to start the motor without delay after the start
command, or
• if the drive is connected to a common DC bus. Otherwise the
charging resistors may be damaged.
Note: The output voltage of the drive can be raised using a parameter
setting; for example, it is possible to run a 500 V motor off a 400 V
supply. Contact your local ABB representative for more information.
Application program set-up
Follow the instructions in the Firmware Manual of the inverter unit to start See the Firmware Manual of the
up the drive and to set the drive parameters. inverter unit.
On-load checks
Check that the Prevention of Unexpected Start function (if installed) Optional function. See delivery
works: specific circuit diagrams.
• Start and Stop the drive and wait until the motor has stopped.
• Open the Prevention of Unexpected Start switch (mounted on a control
desk).
• Give a Start command. The drive should not start.
• Reset the drive.
Check that the cooling fans rotate freely in the right direction, and the air Check visually that the fans rotate in
flows upwards. the direction indicated by an arrow
on the fan housing.
Check the direction of rotation of the motor.
Check the correct operation of the emergency-stop circuits from each
operating location.

104
ACS800-37-specific parameters in the IGBT Supply Control Program

The signals and parameters described in the tables below are included in the IGBT
Supply Control Program.

Term Definition
B Boolean
C Character string
Def. Default value
FbEq Fieldbus equivalent: the scaling between the value shown on the control
panel and the integer used in serial communication
I Integer
R Real
T. Data type (see B, C, I, R)
Parameters
No. Name/Value Description T./FbEq Def.
16 SYSTEM CTR Parameter lock, parameter back-up etc.
INPUTS
16.15 I/O START MODE Selects I/O control start mode when par. 98.01 COMMAND SEL is set B DI2 EDGE
to I/O.
Note: The recommended setting for drives with optional emergency
stop is DI2 LEVEL.
DI2 EDGE Starts the line converter by digital input DI2 rising edge. The line 0
converter starts to modulate and the charging resistors will be by-
passed when the motor-side converter is started.
DI2 LEVEL Starts the line converter by the level of digital input DI2. The line 1
converter starts to modulate and the charging resistors will be by-
passed when the line converter RMIO board is powered, its digital
input DI2 is ON and there are no faults.
Note: With the ACS800-37, this selection changes the value of par.
98.01 COMMAND SEL from the default setting MCW to I/O on the
next RMIO board power-up.
31 AUTOMATIC Automatic fault reset.
RESET Automatic resets are possible only for certain fault types and when the
automatic reset function is activated for that fault type.
The automatic reset function is not operational if the drive is in local
control (L visible on the first row of the control panel display).
WARNING! If the start command is selected and it is ON, the
line converter may restart immediately after automatic fault
reset. Ensure that the use of this feature will not cause
danger.
WARNING! Do not use these parameters when the drive is
connected to a common DC bus. The charging resistors may
be damaged in an automatic reset.
31.01 NUMBER OF TRIALS Defines the number of automatic fault resets the drive performs within I 0
the time defined by parameter 31.02.
0…5 Number of the automatic resets 0

105
No. Name/Value Description T./FbEq Def.

31.02 TRIAL TIME Defines the time for the automatic fault reset function. See parameter R 30 s
31.01.
1.0 … 180.0 s Allowed resetting time 100 …
18000
31.03 DELAY TIME Defines the time that the drive will wait after a fault before attempting R 0s
an automatic reset. See parameter 31.01.
0.0 … 3.0 s Resetting delay 0 … 300
31.04 OVERCURRENT Activates/deactivates the automatic reset for the line converter B NO
overcurrent fault.
NO Inactive 0
YES Active 65535
31.05 OVERVOLTAGE Activates/deactivates the automatic reset for the intermediate link B NO
overvoltage fault.
NO Inactive 0
YES Active 65535
31.06 UNDERVOLTAGE Activates/deactivates the automatic reset for the intermediate link B NO
undervoltage fault.
NO Inactive 0
YES Active 65535
Fixed parameters with the ACS800-37

When the IGBT Supply Control Program is loaded into the ACS800-37, the following
parameters receive the default values given in the table below.
Parameter Default value If changed,
11.01 DC REF SELECT FIELDBUS the default values will be
11.02 Q REF SELECT PARAM 24.02 restored on the next power-
up
98.01 COMMAND SEL MCW. Note: If par. 16.15 I/O
START MODE is set to DI2 LEVEL,
the default value is changed to I/O
on the next RMIO board power-up.
98.02 COMM. MODULE INVERTER
201.09 PANEL DRIVE ID 2
202.01 LOCAL LOCK TRUE
30.02 EARTH FAULT FAULT the default values will not

be restored on the next
power-up. Do not change
them. If the default values
are changed, the drive will
not function.
70.01 CH0 NODE ADDR 120
70.19 CH0 HW CONNECTION RING
70.20 CH3 HW CONNECTION RING
71.01 CH0 DRIVEBUS MODE NO

106
ACS800-37-specific parameters in the application program

The actual signals and parameters described in this section are included in the
ACS800 Standard Application Program.
Term Definition
Actual signal Signal measured or calculated by the drive. Can be monitored by the
user. No user setting possible.
FbEq Fieldbus equivalent: The scaling between the value shown on the control
panel and the integer used in serial communication.
Parameter A user-adjustable operation instruction of the drive.

107
Actual signals and parameters of line-side converter in motor-side converter

program
No. Name/Value Description FbEq Def.
09 ACTUAL SIGNALS Signals from the line converter.
09.12 LCU ACT SIGNAL 1 Line converter signal selected by par. 95.08 LCU PAR1 SEL. 1=1 106
09.13 LCU ACT SIGNAL 2 Line converter signal selected by par. 95.09 LCU PAR2 SEL. 1=1 110
95 HARDWARE SPECIF Line converter references and actual signal selections.
95.06 LCU Q POW REF Reactive power reference for the line converter i.e. the value for 0
par. 24.02 Q POWER REF2 in the IGBT Supply Control Program.
Scaling example 1: 10000 equals to a value of 10000 of parameter
24.02 Q POWER REF2 and 100% of par. 24.01 Q POWER REF
(i.e. 100% of the converter nominal power given in par. 04.06
CONV NOM POWER) when par. 24.03 Q POWER REF2 SEL is
set to PERCENT.
Scaling example 2: Par. 24.03 Q POWER REF2 SEL is set to kVAr.
A value of 1000 of par. 95.06 equals to 1000 kVAr of par. 24.02 Q
POWER REF2. Value of par. 24.01 Q POWER REF is then 100 ·
(1000 kVAr divided by converter nominal power in kVAr)%.
Scaling example 3: Par. 24.03 Q POWER REF2 SEL is set to PHI.
A value of 10000 of par. 95.06 equals to a value of 100 deg of
parameter 24.02 Q POWER REF2 which is limited to 30 deg. The
value of par. 24.01 Q POWER REF will be determined
approximately according to the following equation where P is read
from actual signal 1.09 POWER:
S
P P Q
cos 30 = --- = ------------------------
S 2 2 30 deg
P +Q
P
Positive reference 30 deg denotes capacitive load.
Negative reference 30 deg denotes inductive load.
Par. 24.02 -30 -10 0 10 30 (deg)

Par. 95.06
-10000 -3000 -1000 0 1000 3000 +10000
-10000 ... +10000 Setting range. 1=1

95.07 LCU DC REF (V) DC voltage reference for line converter i.e. the value for par. 23.01 0
DC VOLT REF.
0 … 1100 Setting range in volts. 1=1V
95.08 LCU PAR1 SEL Selects the line-side converter address from which actual signal 106
09.12 LCU ACT SIGNAL 1 is read.
0 … 10000 Parameter index. 1=1
95.09 LCU PAR2 SEL Selects the line-side converter address from which actual signal 110
09.13 LCU ACT SIGNAL 2 is read.
0 … 10000 Parameter index. 1=1

108

109
Maintenance

This chapter contains preventive maintenance instructions.
Safety instructions
Only a qualified electrician is allowed to perform the maintenance.
Before starting work inside the cabinet,
• isolate the drive from the supply (note that any switch-disconnector installed in
the drive does not switch off the voltage from the input terminals)
• wait for 5 minutes to let the intermediate circuit capacitors discharge
• open the cabinet doors
• ensure there is no dangerous voltage present by measuring the voltage of the
input terminals and the intermediate circuit terminals.
Maintenance intervals
If installed in an appropriate environment, the drive requires very little maintenance.
This table lists the routine maintenance intervals recommended by ABB.
Interval Maintenance action Instruction
See document ACS 600/800 Capacitor Reforming

Every year of storage Capacitor reforming Guide (Code: 3BFE 64059629 [English]) and
Capacitors.
Every 6 to 12 months (depending Heatsink temperature

See Heatsinks.
on dustiness of environment) check and cleaning
Air filter check;

Every year (IP22 and IP42 units)
replacement if necessary See Checking and replacing the air filters.
Every year (IP54 units) Air filter replacement
Every 3 years (Frame R8i and Quick connector check

See Quick connectors (Frame R8i and up).
larger units) and cleaning
Cabinet cooling fan

See Cooling fans.
change
Every 6 years
Power module cooling fan
See Cooling fans.
change
Every 10 years Capacitor change See Capacitors.
Maintenance
110
Reduced run capability

If one of the parallel-connected supply or inverter modules must be taken out of the
cabinet for service, it is possible to continue operation at reduced power using the
remaining modules.
Note: This function is only available if the drive is equipped with a PPCS branching
unit of type APBU-xx. (The function is not supported by type NPBU branching units.)
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 84.
3. Fasten the air baffle provided with the unit to the top module guide to block airflow
through the empty module bay.
4. 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

1. Read and repeat the steps in Safety instructions above.
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.
Maintenance
111
Quick connectors (Frame R8i and up)

1. Read and repeat the steps in section Safety instructions above.
2. Open the cabinet doors.
3. Extract one supply or inverter module from the cabinet as described in the
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 supply/inverter module.
7. Repeat steps 3 to 6 for all remaining supply and inverter modules.
8. On frame R8i units (with ALCL-1x-x LCL filter), repeat steps 3 to 6 for the LCL
filter module.
Maintenance
112
Cooling fans
Supply/Inverter module cooling fan replacement (Frame R6)

2. Loosen the fastening screws of the top plate.
3. Lift the top plate upwards and pull it out.
4. Disconnect the fan supply wires (detachable connector).
5. Lift the fan up.
6. Install the new fan in reverse order.
2 2
5
4
Maintenance
113
Supply/Inverter module cooling fan replacement (Frame R7i)

1. Disconnect the wire plug.
2. Remove the two screws holding the fan unit.
3. Pull the fan unit slightly towards the front of the cubicle, then downwards to free it.
4. Install new fan in reverse order.
Maintenance
114
LCL filter module cooling fan replacement (Frame R7i)

1. Disconnect the wire plug (1).
2. Remove the two screws holding the fan unit (2).
3. Pull the fan unit out (3).
2 2
Maintenance
115
Supply and inverter module cooling fan replacement (Frame R8i and up)
The lifespan of the cooling fans of the supply and inverter modules is about 50 000
hours. The actual lifespan depends on the running time of the fan, ambient
temperature and dust concentration. Each supply and inverter module has its own
cooling fan. Replacements are available from ABB. Do not use other than ABB
specified spare parts.
The supply and inverter application programs keep track of the running times of the
cooling fans of the supply and inverter modules respectively. See the Firmware
Manuals delivered with the drive for the actual signals which indicate the running
time.
Module fan replacement procedure
2. Disconnect the fan wiring plug (1).
3. Remove the locking screws (2).
4. Pull the fan out along its sliding rails (3).
5. Install a new fan in reverse order.
Maintenance
116
LCL filter cooling fan replacement (Frame R8i and up)

The lifespan of the cooling fans of the LCL filter modules is about 60 000 hours. The
actual lifespan depends on the running time of the fan, ambient temperature and
dust concentration. Replacements are available from ABB. Do not use other than
ABB specified spare parts.
LCL filter fan replacement procedure
2. Disconnect the fan wiring plug (1).
3. Remove the screws of the fan fastening rail/clip (2).
4. Pull the fan out (3).
5. Install a new fan in reverse order.
ALCL-1x ALCL-2x
2 2
1
3
Maintenance
117
Cabinet fan replacement (Frame R6)

2. Open the cubicle door.
3. Remove the shroud covering the top of the cubicle.
4. Disconnect the fan wiring. Make note of the connections at the terminal block.
5. Undo the two fastening screws that secure the fan holder to the cubicle
roofplate.
6. Pull out the fan holder plate together with the fan.
7. Remove the four screws that fasten the fan to the holder.
Cabinet fan replacement (Frame R8i and up with IP21-42)

The fan is located within the roof structure above the input cubicle as shown in the
picture below.
Fan holder
1. Remove the eight screws attaching the fan holder to the cabinet roof.
2. Lift the fan holder until the fan cable can be disconnected.
3. Disconnect the fan cable.
4. Remove the fan from the fan holder.
5. Fasten a new fan to the fan holder.
6. Reconnect the fan cable.
7. Insert the fan holder into the aperture in the cabinet roof. Make sure the gasket
is not displaced while doing this.
8. Fasten the eight screws attaching the fan holder.
Maintenance
118
Cabinet fan replacement (Frame R8i and up with IP54)

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 fan.
10. Remove the fan capacitor by undoing the fastening screw of the clamp.
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 centred and rotates freely.
2 2 4
1
3
2
2
3
7
6
5
5
Maintenance
119
10
9
8
8
9
8 8
12
11 11
Heatsinks
The heatsink fins of the power modules pick up dust from the cooling air. The module
runs into overtemperature warnings and faults if the heatsinks are not clean. In a
“normal” environment (not especially dusty nor clean) the heatsinks should be
checked annually, in a dusty environment more often.
Whenever necessary, clean the heatsinks as follows:
1. Remove the cooling fan (see section Cooling fans).
2. Blow dry clean 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.
Capacitors
The inverter modules employ several electrolytic capacitors. Their lifespan is at least
90 000 hours depending on the operating time of the drive, loading and ambient
temperature. Capacitor life can be prolonged by lowering the ambient temperature.
It is not possible to predict capacitor failure. Capacitor failure is usually followed by
damage to the unit and an input cable fuse failure, or a fault trip. Contact ABB if
capacitor failure is suspected.
Reforming
Reform (re-age) spare part capacitors once a year according to ACS 600/800
Capacitor Reforming Guide (code: 64059629 [English], available through your local
ABB representative.
Capacitor replacement
Contact an ABB service representative.
Maintenance
120
Other maintenance actions
Power module replacement (Frame R8i and up)

To replace power modules (i.e. supply and inverter modules), follow the instructions
on module removal and refitting given in the chapter Electrical installation.
Maintenance
121
Fault Tracing
Faults and warnings displayed by the CDP-312R Control Panel

The control panel will display the warnings and faults of the unit (i.e. supply unit or
inverter unit) the panel is currently controlling.
The warnings and faults concerning the inverter unit (motor-side converter) are dealt
with in the application program (e.g. Standard Application Program) Firmware
Manual.
Warning/Fault message from unit not being monitored by control panel

Flashing messages WARNING, ID:2 or FAULT, ID:2 on the control panel display
indicate a warning or fault state in the line-side converter when the panel is
controlling the motor-side converter:
FAULT, ID:2
ACS 800 0490_3MR
*** FAULT ***
LINE CONV (FF51)
To display the warning or fault identification text, switch the control panel to view the
line-side converter as described in section Control panel on page 37.
Conflicting ID numbers
If the ID numbers of the line-side and the motor-side converters are set equal, the
control panel stops functioning. To clear the situation:
• Disconnect the panel cable from the RMIO board of the motor-side converter.
• Set the ID number of the line-side converter RMIO board to 2. For the setting
procedure, see the application program (e.g. Standard Application Program)
Firmware Manual.
• Connect the disconnected cable to the RMIO board of the motor-side converter
again and set the ID number to 1.
Fault Tracing
122
LEDs of the drive
Location LED Indication
RMIO board (RDCU drive control Red Fault state.

unit)
Green The power supply on the board is OK.
Control panel mounting platform Red Fault state.
(with the control panel removed)
Green The main + 24 V power supply for the control panel and the
RMIO board is OK.
AINT board (visible through the V204 (green) +5 V voltage of the board is OK.
transparent cover on the front of the
V309 (red) Prevention of unexpected start is ON.
supply and inverter modules)
V310 (green) IGBT control signal transmission to the gate driver control
boards is enabled.
Fault Tracing
123
Technical data

This chapter contains the technical specifications of the drive, e.g. ratings, frame
sizes and technical requirements, provisions for fulfilling the requirements for CE
and other markings, and warranty information.
IEC ratings
The ratings for the ACS800-37 with a 50 Hz supply are given below. The symbols
are described below the table.
Nominal No-over- Light- Heavy-duty Heat dissi- Air Noise
ratings load use overload use use pation flow level
ACS800-37 type
Icont.max Imax Pcont.max I2N PN I2hd Phd
A A kW A kW A kW kW m3/h dBA
Three-phase supply voltage 380 V, 400 V or 415 V
ACS800-37-0060-3 120 168 55 114 55 88 45 1.8 500 73
ACS800-37-0070-3 150 234 75 142 75 117 55 2.4 500 73
ACS800-37-0100-3 165 264 90 157 75 132 75 2.8 500 73
ACS800-37-0140-3 202 293 110 194 90 151 75 6 1300 74
ACS800-37-0170-3 250 363 132 240 132 187 90 7 1300 74
ACS800-37-0210-3 292 400 160 280 160 218 110 8 3160 75
ACS800-37-0260-3 370 506 200 355 200 277 132 10 3160 75
ACS800-37-0320-3 469 642 250 450 250 351 200 13 3160 75
ACS800-37-0390-3 565 773 315 542 315 423 250 16 3160 75
ACS800-37-0510-3 730 1000 400 701 355 546 250 23 3160 75
ACS800-37-0640-3 919 1258 500 882 500 688 355 24 6400 77
ACS800-37-0770-3 1111 1521 630 1067 630 831 450 31 6400 77
ACS800-37-0960-3 1379 1888 800 1324 710 1031 560 43 6400 77
ACS800-37-1070-3 1535 2102 900 1474 800 1149 630 46 10240 78
ACS800-37-1430-3 2056 2814 1200 1973 1100 1538 800 63 10240 78
ACS800-37-1810-3 2610 3573 1600 2506 1400 1953 1100 83 12800 79
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V
ACS800-37-0070-5 120 168 75 114 75 88 55 2.4 500 73
ACS800-37-0100-5 139 234 90 132 90 114 75 2.8 500 73
ACS800-37-0120-5 156 264 110 148 (1 90 125 75 3.4 500 73
ACS800-37-0170-5 200 291 132 192 132 150 90 6 1300 74
ACS800-37-0210-5 245 355 160 235 (2 160 183 110 8 1300 74
ACS800-37-0260-5 302 438 200 289 (3 200 226 132 9 3160 75
ACS800-37-0320-5 365 530 250 350 (4 250 273 160 11 3160 75
ACS800-37-0400-5 455 660 315 437 315 340 200 14 3160 75
ACS800-37-0460-5 525 762 355 504 355 393 250 16 3160 75
ACS800-37-0510-5 595 863 400 571 400 445 315 18 3160 75
ACS800-37-0610-5 700 1016 500 672 450 524 315 23 3160 75
ACS800-37-0780-5 892 1294 630 856 630 667 450 26 6400 77
ACS800-37-0870-5 1005 1458 710 965 630 752 500 32 6400 77
ACS800-37-1160-5 1338 1941 900 1284 900 1001 710 44 6400 77
ACS800-37-1330-5 1528 2217 1120 1467 1120 1143 800 46 10240 78
Technical data
124
Nominal No-over- Light- Heavy-duty Heat dissi- Air Noise

ratings load use overload use use pation flow level
ACS800-37 type
Icont.max Imax Pcont.max I2N PN I2hd Phd
A A kW A kW A kW kW m3/h dBA
ACS800-37-1820-5 2037 2956 1400 1956 1300 1524 1000 67 10240 78
ACS800-37-2200-5 2529 3670 1800 2428 1700 1892 1350 81 12800 79
Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V, or 690 V
ACS800-37-0170-7 139 202 132 133 110 104 90 8 1300 74
ACS800-37-0210-7 162 235 160 156 132 121 110 9 1300 74
ACS800-37-0260-7 201 301 200 193 160 150 132 12 3160 75
ACS800-37-0320-7 279 417 250 268 250 209 200 15 3160 75
ACS800-37-0400-7 335 502 315 322 250 251 200 18 3160 75
ACS800-37-0440-7 382 571 355 367 355 286 270 19 3160 75
ACS800-37-0540-7 447 668 450 429 400 334 315 21 3160 75
ACS800-37-0790-7 659 985 630 632 630 493 450 35 6400 77
ACS800-37-0870-7 729 1091 710 700 710 545 500 37 6400 77
ACS800-37-1160-7 953 1425 900 914 900 713 710 46 6400 77
ACS800-37-1330-7 1112 1663 1120 1067 1120 831 800 54 10240 78
ACS800-37-1510-7 1256 1879 1250 1206 1200 940 900 62 10240 78
ACS800-37-2320-7 1866 2791 1800 1791 1750 1396 1400 89 12800 79
ACS800-37-2780-7 2321 3472 2300 2228 2300 1736 1600 106 17920 79
ACS800-37-3310-7 2665 3987 2700 2559 2600 1999 2000 121 19200 79
1) 156 A allowed at 460 V
PDM-184674-G5
Symbols
Nominal ratings
Icont.max Continuous RMS output current. No overloadability at 40 °C (104 °F).
Imax Maximum output current. Allowable for 10 seconds at start, otherwise as long as allowed
by drive temperature.
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).
Technical data
125
Derating
The load capacity (current and power) decreases if the installation site altitude exceeds 1000 metres
(3281 ft), or if the ambient temperature exceeds 40 °C (104 °F).
Temperature derating
In the temperature range +40 °C (+104 °F) to +50 °C (+122 °F), the rated output current is decreased
by 1% for every additional 1 °C (1.8 °F). The output current is calculated by multiplying the current
given in the rating table by the derating factor.
Example If the ambient temperature is 50 °C (+122 °F), the derating factor is 100 % - 1 % · 10 °C =
90% or 0.90. The output current is then 0.90 × I or 0.90 × I . °C
2N cont.max
Altitude derating
At altitudes from 1000 to 4000 m (3281 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
126
NEMA ratings
The ratings for the ACS800-37 with a 60 Hz supply are given below. The symbols
are described below the table.
Heavy-duty Heat dis- Noise
Nominal ratings Normal use Air flow
use sipation level
ACS800-37 type
Imax Pcont.max I2N PN I2hd Phd
A HP A HP A HP Btu/h ft3/min dBA
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V or 480 V
ACS800-37-0070-5 168 75 114 75 88 60 8200 295 73
ACS800-37-0100-5 234 100 132 100 114 75 9600 295 73
ACS800-37-0120-5 264 125 156 125 125 100 11600 295 73
ACS800-37-0170-5 291 150 192 150 156 125 20500 765 74
ACS800-37-0210-5 355 200 240 200 183 150 27300 765 74
ACS800-37-0260-5 438 250 302 250 226 150 30700 1860 75
ACS800-37-0320-5 530 300 361 300 273 200 37600 1860 75
ACS800-37-0400-5 660 350 437 350 340 250 47800 1860 75
ACS800-37-0460-5 762 450 504 400 393 300 54700 1860 75
ACS800-37-0510-5 863 500 571 450 445 350 61500 1860 75
ACS800-37-0610-5 1016 550 672 550 524 400 78600 1860 75
ACS800-37-0780-5 1294 750 856 700 667 550 88800 3770 77
ACS800-37-0870-5 1458 900 965 800 752 650 109000 3770 77
ACS800-37-1160-5 1941 1150 1284 1050 1001 850 150000 3770 77
ACS800-37-1330-5 2217 1300 1467 1250 1143 1000 157000 6030 78
ACS800-37-1820-5 2956 1650 1956 1650 1524 1250 229000 6030 78
ACS800-37-2200-5 3670 2150 2428 2050 1892 1600 277000 7530 79
ACS800-37-0170-7 202 125 133 125 104 100 27300 765 74
ACS800-37-0210-7 235 150 156 150 121 100 30700 765 74
ACS800-37-0260-7 301 200 193 200 150 150 41000 1860 75
ACS800-37-0320-7 417 250 268 250 209 200 51200 1860 75
ACS800-37-0400-7 502 350 322 300 251 250 61500 1860 75
ACS800-37-0440-7 571 400 367 350 286 300 64900 1860 75
ACS800-37-0540-7 668 450 429 450 334 350 71700 1860 75
ACS800-37-0790-7 985 700 632 650 493 500 120000 3770 77
ACS800-37-0870-7 1091 800 700 750 545 600 126000 3770 77
ACS800-37-1160-7 1425 950 914 1000 713 750 157000 3770 77
ACS800-37-1330-7 1663 1250 1067 1150 831 900 185000 6030 78
ACS800-37-1510-7 1879 1350 1206 1300 940 1050 212000 6030 78
ACS800-37-2320-7 2791 1850 1791 2000 1396 1500 304000 7530 79
ACS800-37-2780-7 3472 2600 2228 2450 1736 1900 362000 10550 79
ACS800-37-3310-7 3987 3000 2559 2800 1999 2200 413000 11300 79
PDM-184674-G18
Technical data
127
Symbols
Nominal ratings
Imax Maximum output current. Allowable for 10 seconds at start, otherwise as long as allowed
by drive temperature.
Pcont.max Typical motor power. The power ratings apply to most 4-pole NEMA-rated motors at
nominal voltage (460 or 575 V).
Normal 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 4-pole NEMA-rated motors at
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 4-pole NEMA-rated motors at
Note: The ratings apply in an ambient temperature of 40 °C (104 °F). In lower

temperatures, the ratings are higher.
Technical data
128
ACS800-37 frame sizes and power module types

Supply module(s) used LCL filter(s) used Inverter modules used
ACS800-37 type Frame size
Qty Type Qty Type Qty Type
ACS800-37-0060-3 R6 1 ACS800-11-0060-3* N/A N/A
ACS800-37-0070-3 R6 1 ACS800-11-0070-3* N/A N/A
ACS800-37-0100-3 R6 1 ACS800-11-0100-3* N/A N/A
ACS800-37-0140-3 R7i 1 ACS800-104-0145-3 1 ALCL-04-5 1 ACS800-104-0145-3
ACS800-37-0640-3 2×R8i 2 ACS800-104-0390-3 1 ALCL-24-5 2 ACS800-104-0320-3
Three-phase supply voltage 380 V, 400 V, 415 V, 440 V, 460 V, 480 V or 500 V
ACS800-37-0070-5 R6 1 ACS800-11-0070-5* N/A N/A
ACS800-37-0100-5 R6 1 ACS800-11-0100-5* N/A N/A
ACS800-37-0120-5 R6 1 ACS800-11-0120-5* N/A N/A
Three-phase supply voltage 525 V, 550 V, 575 V, 600 V, 660 V, or 690 V
*Integrated supply module, LCL filter and inverter module
PDM-184674-E22
Technical data
129
AC fuses
Notes:
• Larger fuses must not be used.
• Fuses from other manufacturers can be used if they meet the ratings.
• The recommended fuses are for branch circuit protection per NEC as required for
UL approval.
AC fuse information
Drive type aR, IEC aR, UL Recognized
Qty In
Bussmann Ferraz Shawmut Bussmann Ferraz Shawmut
400 V
ACS800-37-0060-3 3 160 170M3814 – 170M3014 –
ACS800-37-0070-3 3 200 170M3815 – 170M3015 –
ACS800-37-0100-3 3 250 170M3816 – 170M3016 –
ACS800-37-0140-3 3 315 170M3817 – 170M3017 –
ACS800-37-0170-3 3 400 170M5808 – 170M5008 –
ACS800-37-0210-3 3 450 170M5809 6.9URD2PV0450 170M5059 –
ACS800-37-0260-3 3 630 170M6810 6.9URD3PV0630 170M6210 –
ACS800-37-0320-3 3 800 170M8545 6.9URD3PV0800 170M6212 –
ACS800-37-0390-3 3 1000 170M6814 6.9URD3PV1000 170M6214 –
ACS800-37-0510-3 3 1000 170M6814 6.9URD3PV1000 170M6214 –
ACS800-37-0640-3 3 1600 170M6419 6URD33TTF1600 170M6419 6URD33TTF1600
ACS800-37-0770-3 3 2000 170M6421 5.5URD33TTF2000 170M6421 5.5URD33TTF2000
500 V
ACS800-37-0070-5 3 160 170M3814 – 170M3014 –
ACS800-37-0100-5 3 200 170M3815 – 170M3015 –
ACS800-37-0120-5 3 250 170M3816 – 170M3016 –
ACS800-37-0170-5 3 315 170M3817 – 170M3017 –
ACS800-37-0210-5 3 400 170M5808 – 170M5008 –
ACS800-37-0260-5 3 450 170M5809 6.9URD2PV0450 170M5059 –
ACS800-37-0320-5 3 630 170M6810 6.9URD3PV0630 170M6210 –
ACS800-37-0400-5 3 800 170M8545 6.9URD3PV0800 170M6212 –
ACS800-37-0460-5 3 1000 170M6814 6.9URD3PV1000 170M6214 –
ACS800-37-0510-5 3 1000 170M6814 6.9URD3PV1000 170M6214 –
ACS800-37-0610-5 3 1000 170M6814 6.9URD3PV1000 170M6214 –
690 V
ACS800-37-0170-7 3 250 170M3816 – 170M3016 –
ACS800-37-0210-7 3 315 170M3817 – 170M3017 –
ACS800-37-0260-7 3 315 170M3817 6.9URD1PV0315 170M3017 –
ACS800-37-0320-7 3 450 170M5809 6.9URD2PV0450 170M5059 –
ACS800-37-0400-7 3 450 170M5809 6.9URD2PV0450 170M5059 –
ACS800-37-0440-7 3 630 170M6810 6.9URD3PV0630 170M6210 –
ACS800-37-0540-7 3 630 170M6810 6.9URD3PV0630 170M6210 –
ACS800-37-0870-7 3 1250 170M6416 – 170M6416 –
ACS800-37-1160-7 3 1250 170M6416 – 170M6416 –
ACS800-37-2320-7 6 1250 170M6416 – 170M6416 –
ACS800-37-2780-7 9 1250 170M6416 – 170M6416 –
ACS800-37-3310-7 9 1250 170M6416 – 170M6416 –
PDM-184674-G5
Technical data
130
DC fuses
Notes:
• Larger fuses must not be used.
• Fuses from other manufacturers can be used if they meet the ratings.
• The recommended fuses are for branch circuit protection per NEC as required for
UL approval.
DC fuse information
Drive type IEC UL Recognized
Qty
Bussmann Ferraz Shawmut In Bussmann In
400 V
ACS800-37-0060-3
… – – – – – –
ACS800-37-0510-3
ACS800-37-0640-3 8 170M8552 6.9URD3PV1000 1000 170M6215 1000
ACS800-37-0770-3 8 170M8547 6.9URD33PA1250 1250 170M6216 1250
ACS800-37-0960-3 8 170M8547 6.9URD33PA1250 1250 170M6216 1250
ACS800-37-1070-3 12 170M8552 6.9URD3PV1000 1000 170M6215 1000
ACS800-37-1430-3 12 170M8547 6.9URD33PA1250 1250 170M6216 1250
ACS800-37-1810-3 16 170M8547 6.9URD33PA1250 1250 170M6216 1250
500 V
ACS800-37-0070-5
… – – – – – –
ACS800-37-0610-5
ACS800-37-0780-5 8 170M8552 6.9URD3PV1000 1000 170M6215 1000
ACS800-37-0870-5 8 170M8552 6.9URD3PV1000 1000 170M6215 1000
ACS800-37-1160-5 8 170M8547 6.9URD33PA1250 1250 170M6216 1250
ACS800-37-1330-5 12 170M8547 6.9URD33PA1250 1250 170M6216 1250
ACS800-37-1820-5 12 170M8547 6.9URD33PA1250 1250 170M6216 1250
ACS800-37-2200-5 16 170M8547 6.9URD33PA1250 1250 170M6216 1250
690 V
ACS800-37-0170-7
… – – – – – –
ACS800-37-0540-7
ACS800-37-0790-7 8 170M8646 12URD73PA0700 700 170M8636 700
ACS800-37-0870-7 8 170M8647 11URD73PA0800 800 170M8637 800
ACS800-37-1160-7 8 170M8647 11URD73PA0800 800 170M8637 800
ACS800-37-1330-7 12 170M8647 11URD73PA0800 800 170M8637 800
ACS800-37-1510-7 12 170M8647 11URD73PA0800 800 170M8637 800
ACS800-37-2320-7 16 170M8647 11URD73PA0800 800 170M8637 800
ACS800-37-2780-7 24 170M8647 11URD73PA0800 800 170M8637 800
ACS800-37-3310-7 24 170M8647 11URD73PA0800 800 170M8637 800
PDM-184674-G5
Technical data
131
Input power connection

Voltage (U1) 380/400/415 VAC 3-phase ± 10% for 400 VAC units
380/400/415/440/460/480/500 VAC 3-phase ± 10% for 500 VAC units
525/550/575/600/660/690 VAC 3-phase ± 10% for 690 VAC units
Prospective short-circuit 65 kA (Icf) for units without grounding switch.

current (IEC 60439-1, 50 kA (Icf) for units with grounding switch.
UL508C)
US/Canada: The drive is suitable for use in a circuit capable of delivering not more than
65,000 A rms symmetrical at drive nominal voltage when protected by aR fuses.
Frequency 50 ± 2 Hz or 60 ± 2 Hz. Maximum rate of change 17 %/s
Imbalance Max. ± 3% of nominal phase-to-phase input voltage
Voltage dips Max. 25%
Power factor cosphi = 1.00 (fundamental at nominal load)

I1
- ⋅ cosphi > 0.98
--------- I1 = fundamental input current rms value
I rms
Irms = total input current rms value
Harmonic distortion Harmonics are below the limits defined in IEEE519 for all Isc/IL. Each individual harmonic
current fulfils IEEE519 table 10-3 for Isc/IL > 20. Current THD and each individual current
harmonic fulfil IEC 61000-3-4 table 5.2 for R sce > 66. The values will be met if the supply
network voltage is not distorted by other loads.
Input power cable lead- Ø60 mm. For quantity and location, see the chapter Dimensions.
throughs
Technical data
132
Input terminals L1/L2/L3 – Bottom cable entry/exit

Frame R6
Front view
Bolt size: M10
Tightening torque: 40 Nm (29.5 lbf.ft)
Top cable entry/exit

Front view
Bolt size: M10
Input terminals L1/L2/L3 – Side view

Frame R7i Bolt size: M12 or ½”
Tightening torque: 70 Nm (52 lbf.ft)
Technical data
133
Input terminals L1/L2/L3 – Front view

Frame R8i Bolt size: M12 or ½”
Input terminals L1/L2/L3 – Front view

Frame 2×R8i and up Bolt size: M12 or ½”
Motor connection
Voltage (U2) 0 to U1, 3-phase symmetrical, Umax at the field weakening point
Frequency DTC mode: 0 to 3.2 × fFWP. Maximum frequency 300 Hz.
U Nmains
fFWP = · fNmotor
UNmotor
where fFWP = frequency at field weakening point; UNmains = mains (input power) voltage;
U Nmotor = rated motor voltage; fNmotor = rated motor frequency
Frequency resolution 0.01 Hz
Current See section IEC ratings.
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 2…3 kHz (average)
Motor cable lead-throughs 3 × Ø60 mm at each inverter module (units without common motor terminal cubicle)
Units with common motor terminal cubicle: See the chapter Dimensions.
Technical data
134
Output terminals U2/V2/W2 Bottom cable entry/exit

– Frame R6
Front view
Bolt size: M10
Top cable entry/exit

Front view
Bolt size: M10
Output terminals U2/V2/W2 Front view

– Frame R7i Bolt size: M12 or ½”
Technical data
135
Standard output terminals Bottom or top exit

U2/V2/W2 – Frame R8i Front view
Frame R8i units without option Bolt size: M12 or ½”
+E202 (EMC/RFI filtering for Tightening torque: 70 Nm (52 lbf.ft)
1st Environment) or +H359
(common motor terminal
cubicle)
Output terminals at each R8i

Bottom exit Top exit
inverter module
Side view Side view
Frame R8i units with option Bolt size: M12 or ½” Bolt size: M12 or ½”
+E202 (EMC/RFI filtering for Tightening torque: 70 Nm (52 lbf.ft) Tightening torque: 70 Nm (52 lbf.ft)
1st Environment) but without
option +H359 (common motor
terminal cubicle)
Frame 2×R8i and larger units
without option +H359
Cabling
direction
Cabling direction
68265631-B cabinet_400_generic.asm
Output terminals 8 × Ø13 mm per phase. Tightening torque: 70 Nm (52 lbf.ft). See the chapter Dimensions.
Units with option +H359
(common motor terminal
cubicle)
Technical data
136
Maximum recommended 100 m (328 ft). Motor cables up to 500 m (1640 ft) long are allowed but EMC filtering
motor cable length within the specified limits will not be realised.
Efficiency
> 97% (at rated current and nominal supply voltage)
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 Mechanical installation.
Cooling air flow See IEC ratings.
Degrees of protection
IP21; IP22; IP42; IP54, IP54R (with air outlet duct)
Ambient conditions
Environmental limits for the drive are given below. The drive is to be used in a heated,
indoor, controlled environment.
Operation Storage Transportation
installed for stationary use in the protective package in the protective package
Installation site altitude 0 to 4000 m (13123 ft) above - -
sea level [above 1000 m
(3281 ft), see section
Derating]
Air temperature -15 to +50 °C (5 to 122 °F). -40 to +70 °C (-40 to +158°F) -40 to +70 °C (-40 to +158°F)
See section Derating.
Relative humidity 5 to 95% Max. 95% Max. 95%
No condensation allowed. Maximum allowed relative humidity is 60% in the presence of
corrosive gases.
Contamination levels No conductive dust allowed.
(IEC 60721-3-3, IEC 60721-3- Boards without coating: Boards without coating: Boards without coating:
2, IEC 60721-3-1) Chemical gases: Class 3C1 Chemical gases: Class 1C2 Chemical gases: Class 2C2
Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2
Boards with coating: Boards with coating: Boards with coating:
Chemical gases: Class 3C2 Chemical gases: Class 1C2 Chemical gases: Class 2C2
Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2
Atmospheric pressure 70 to 106 kPa 70 to 106 kPa 60 to 106 kPa
0.7 to 1.05 atmospheres 0.7 to 1.05 atmospheres 0.6 to 1.05 atmospheres
Vibration (IEC 60068-2) Max. 1 mm (0.04 in.) Max. 1 mm (0.04 in.) Max. 3.5 mm (0.14 in.)
(5 to 13.2 Hz), (5 to 13.2 Hz), (2 to 9 Hz),
max. 7 m/s2 (23 ft/s2) max. 7 m/s2 (23 ft/s2) max. 15 m/s2 (49 ft/s2)
(13.2 to 100 Hz) sinusoidal (13.2 to 100 Hz) sinusoidal (9 to 200 Hz) sinusoidal
Technical data
137
Shock (IEC 60068-2-29) Not allowed Max. 100 m/s2 (330 ft./s2), Max. 100 m/s2 (330 ft./s2),
11 ms 11 ms
Free fall Not allowed 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) steel sheet (thickness 1.5 mm) with
polyester thermosetting powder coating (thickness approx. 80 µm) on visible surfaces.
Colour: RAL 7035 (light grey, semigloss).
Busbars Tin- or silver-plated copper
Fire safety of materials Insulating materials and non-metallic items: Mostly self-extinctive
(IEC 60332-1)
Packaging Frame: Wood or plywood. Plastic wrapping: PE-LD. Bands: PP or steel.
Disposal The drive contains raw materials that should be recycled to preserve energy and natural
resources. The package materials are environmentally compatible and recyclable. All
metal parts can be recycled. The plastic parts can either be recycled or burned under
controlled circumstances, according to local regulations. Most recyclable parts are marked
with recycling marks.
If recycling is not feasible, all parts excluding electrolytic capacitors and printed circuit
boards can be landfilled. The DC capacitors (C1-1 to C1-x) contain electrolyte and the
printed circuit boards contain lead, both of which are classified as hazardous waste within
the EU. They must be removed and handled according to local regulations.
For further information on environmental aspects and more detailed recycling instructions,
please contact your local ABB distributor.
Tightening torques for power connections

Screw size Torque
M5 3.5 Nm (2.6 lbf.ft)
M6 9 Nm (6.6 lbf.ft)
M8 20 Nm (14.8 lbf.ft)
M10 40 Nm (29.5 lbf.ft)
M12 70 Nm (52 lbf.ft)
M16 180 Nm (133 lbf.ft)
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) Insulation coordination for equipment within low-voltage systems. Part 1: Principles,
requirements and tests.
Technical data
138
• EN 61800-3 (2004) Adjustable speed electrical power drive systems. Part 3: EMC requirements and specific
test methods
• UL 508C UL Standard for Safety, Power Conversion Equipment, second edition
• CSA C22.2 No. 14-95 Industrial control equipment
Technical data
139
CE marking
A CE mark is attached to the drive to verify that the unit follows the provisions of the European Low
Voltage and EMC Directives (Directive 73/23/EEC, as amended by 93/68/EEC and Directive 89/336/
EEC, as amended by 93/68/EEC).
Definitions
EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to
operate without problems within an electromagnetic environment. Likewise, the equipment must not
disturb or interfere with any other product or system within its locality.
First environment includes establishments connected to a low-voltage network which supplies buildings
used for domestic purposes.
Second environment includes establishments connected to a network not supplying domestic premises.
Drive of category C2: drive of rated voltage less than 1000 V and intended to be installed and
commissioned only by a professional when used in the first environment. Note: A professional is a
person or organisation having necessary skills in installing and/or commissioning power drive systems,
including their EMC aspects.
Drive of category C3: drive of rated voltage less than 1000 V and intended for use in the second
environment and not intended for use in the first environment.
Drive of category C4: drive of rated voltage equal to or above 1000 V, or rated current equal to or above
400 A, or intended for use in complex systems in the second environment.
Compliance with the EMC Directive

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

First environment (drive of category C2)
The drive complies with the standard with the following provisions:
1. The drive is equipped with EMC filter +E202.
2. The motor and control cables are selected as specified in the Hardware Manual.
3. The drive is installed according to the instructions given in the Hardware Manual.
4. Maximum cable length is 100 metres (328 ft).
WARNING! In a domestic environment, this product may cause radio interference, in which case
supplementary mitigation measures may be required.
Note: It is not allowed to install a drive equipped with EMC filter +E202 on IT (unearthed) systems. The
supply network becomes connected to earth potential through the EMC filter capacitors which may
cause danger or damage the unit.
Technical data
140
Second environment (drive of category C3)

1. The drive is equipped with EMC filter +E200. The filter is suitable for TN (earthed) and IT
(unearthed) networks.
2. The motor and control cables are selected as specified in the drive manuals.
3. The drive is installed according to the instructions given in the drive manuals.
WARNING! A drive of category C3 is not intended to be used on a low-voltage public network which
supplies domestic premises. Radio frequency interference is expected if the drive is used on such a
network.
If the provisions under Second environment (drive of category C3) cannot be met, e.g. the drive cannot
be equipped with EMC filter +E200 when installed in an IT (unearthed) network, the requirements of the
EMC Directive can be met as follows:
1. It is ensured that no excessive emission is propagated to neighbouring low-voltage networks. In
some cases, the natural suppression in transformers and cables is sufficient. If in doubt, the supply
transformer with static screening between the primary and secondary windings can be used.
Medium voltage network

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

Equipment
Drive
(victim)
Equipment Equipment
2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available
from the local ABB representative.
network.
Machinery Directive
The drive complies with the European Union Machinery Directive (98/37/EC) requirements for an
equipment intended to be incorporated into machinery.
Technical data
141
“C-tick” marking
“C-tick” marking is required in Australia and New Zealand. A “C-tick” mark is attached to each drive in
order to verify compliance with the relevant standard (IEC 61800-3 (2004) – Adjustable speed electrical
power drive systems. Part 3: EMC product standard including specific test methods), mandated by the
Trans-Tasman Electromagnetic Compatibility Scheme.
Definitions
EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to
operate without problems within an electromagnetic environment. Likewise, the equipment must not
disturb or interfere with any other product or system within its locality.
The Trans-Tasman Electromagnetic Compatibility Scheme (EMCS) was introduced by the Australian
Communication Authority (ACA) and the Radio Spectrum Management Group (RSM) of the New
Zealand Ministry of Economic Development (NZMED) in November 2001. The aim of the scheme is to
protect the radiofrequency spectrum by introducing technical limits for emission from electrical/
electronic products.
First environment includes establishments connected to a low-voltage network which supplies buildings
used for domestic purposes.
Second environment includes establishments connected to a network not supplying domestic premises.
Drive of category C2: drive of rated voltage less than 1000 V and intended to be installed and
commissioned only by a professional when used in the first environment. Note: A professional is a
person or organisation having necessary skills in installing and/or commissioning power drive systems,
including their EMC aspects.
Drive of category C3: drive of rated voltage less than 1000 V and intended for use in the second
environment and not intended for use in the first environment.
Drive of category C4: drive of rated voltage equal to or above 1000 V, or rated current equal to or above
400 A, or intended for use in complex systems in the second environment.
Compliance with the EN 61800-3 (2004)

First environment (drive of category C2)
1. The drive is equipped with EMC filter +E202.
WARNING! In a domestic environment, this product may cause radio interference, in which case
supplementary mitigation measures may be required.
Note: It is not allowed to install a drive equipped with EMC filter +E202 on IT (unearthed) systems. The
supply network becomes connected to earth potential through the EMC filter capacitors which may
cause danger or damage the unit.
Technical data
142

1. The drive is equipped with EMC filter +E200. The filter is suitable for TN (earthed) and IT
(unearthed) networks.
2. The motor and control cables are selected as specified in the drive manuals.
3. The drive is installed according to the instructions given in the drive manuals.
network.
If the provisions under Second environment (drive of category C3) cannot be met, e.g. the drive cannot
be equipped with EMC filter +E200 when installed in an IT (unearthed) network, the requirements of the
EMC Directive can be met as follows:
1. It is ensured that no excessive emission is propagated to neighbouring low-voltage networks. In
some cases, the natural suppression in transformers and cables is sufficient. If in doubt, the supply
transformer with static screening between the primary and secondary windings can be used.
Medium voltage network

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

Equipment
Drive
(victim)
Equipment Equipment
2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available
from the local ABB representative.
network.
Technical data
143
Equipment warranty and liability

The manufacturer warrants the equipment supplied against defects in design, materials and
workmanship for a period of twelve (12) months after installation or twenty-four (24) months from date
of manufacturing, whichever first occurs. The local ABB office or distributor may grant a warranty period
different to the above and refer to local terms of liability as defined in the supply contract.
The manufacturer is not responsible for
• any costs resulting from a failure if the installation, commissioning, repair, alternation, or ambient
conditions of the drive do not fulfil the requirements specified in the documentation delivered with
the unit and other relevant documentation.
• units subjected to misuse, negligence or accident
• units comprised of materials provided or designs stipulated by the purchaser.
In no event shall the manufacturer, its suppliers or subcontractors be liable for special, indirect,
incidental or consequential damages, losses or penalties.
THIS IS THE SOLE AND EXCLUSIVE WARRANTY GIVEN BY THE MANUFACTURER WITH
RESPECT TO THE EQUIPMENT AND IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES,
EXPRESS OR IMPLIED, ARISING BY OPERATION OF LAW OR OTHERWISE, INCLUDING, BUT
NOT LIMITED TO, ANY IMPLIED WARRANTIES OR MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.
If you have any questions concerning your ABB drive, please contact the local distributor or ABB office.
The technical data, information and specifications are valid at the time of printing. The manufacturer
reserves the right to modifications without prior notice.
Technical data
144
Technical data
145
Dimensions

This chapter contains a table of weights as well as dimensional drawings of the
different frame sizes of the ACS800-37.
Weights
The following table shows the approximate weights of all ACS800-37 types (without
options).
Weight
ACS800-37-…
kg lb
0060-3 0070-5
0070-3 0100-5 250 550
0100-3 0120-5
0140-3 0170-5 0170-7
400 880
0170-3 0210-5 0210-7
0210-3 0260-5 0260-7
0260-3 0320-5 0320-7
0320-3 0400-5 0400-7
950 2090
0390-3 0460-5 0440-7
0510-3 0510-5 0540-7
0610-5
0640-3 0780-5 0790-7
0770-3 0870-5 0870-7 2000 4410
0960-3 1160-5 1160-7
1070-3 1330-5 1330-7
3060 6750
1430-3 1820-5 1510-7
1810-3 2200-5 2320-7 3600 7940
2780-7 4780 10540
3310-7 4930 10870
Dimensions
146
Frame R6
Dimensions
147
[Frame size R6 continued]
Dimensions
148
Dimensions
149
Dimensions
150
Frame R7i
Dimensions
151
[Frame size R7i continued]
Dimensions
152
Dimensions
153
Dimensions
154
Dimensions
155
Dimensions
156
Dimensions
157
Frame R8i (without option +E202)
Dimensions
158
[Frame size R8i (without option +E202) continued]
Dimensions
159
Dimensions
160
Dimensions
161
Dimensions
162
Dimensions
163
Dimensions
164
Dimensions
165
Frame size R8i (with option +E202)
Dimensions
166
[Frame size R8i (with option +E202) continued]
Dimensions
167
Dimensions
168
Dimensions
169
Dimensions
170
Frame size 2×R8i
Dimensions
171
(Frame size 2×R8i continued)
Dimensions
172
Dimensions
173
Dimensions
174
Dimensions
175
Dimensions
176
Dimensions
177
Dimensions
178
Dimensions
179
Dimensions
180
Dimensions
181
Dimensions
182
Dimensions
183
Frame size 3×R8i
Dimensions
184
Dimensions
185
Dimensions
186
Dimensions
187
Dimensions
188
Dimensions
189
Frame size 4×R8i
Dimensions
190
Dimensions
191
Dimensions
192
Dimensions
193
Dimensions
194
Dimensions
195
Frame size 5×R8i
Dimensions
196
Dimensions
197
Dimensions
198
Dimensions
199
Dimensions
200
Dimensions
201
Dimensions
202
Dimensions
203
Dimensions
204
Dimensions
205
Dimensions
206
Dimensions
207
Frame size 6×R8i
Dimensions
208
Dimensions
209
Dimensions
210
Dimensions
211
Dimensions
212
Dimensions
213
Dimensions
214
Dimensions
215
Dimensions
216
Dimensions
217
Dimensions
218
Dimensions
219
Resistor braking

This chapter describes the resistor braking options of the ACS800-37.
Resistor braking options

The following ACS800-37 drives are available with brake choppers and resistors.
For information on braking equipment for other ACS800-37 types, or custom resistor
braking equipment, contact your local ABB representative.
UN ACS800-37 type Brake chopper type (+D150) Brake resistor type (+D151)
ACS800-37-0060-3
••• NBRA-658 2 × SAFUR210F575
ACS800-37-0170-3
ACS800-37-0210-3
400 V ••• NBRA-659 2 × SAFUR180F460
ACS800-37-0510-3
ACS800-37-0640-3
2 × NBRA-659 2 × (2 × SAFUR180F460)
ACS800-37-0770-3
ACS800-37-0960-3 3 × NBRA-659 3 × (2 × SAFUR180F460)
ACS800-37-0070-5
••• NBRA-658 2 ×SAFUR125F500
ACS800-37-0210-5
ACS800-37-0260-5
500 V ••• NBRA-659 2 × SAFUR200F500
ACS800-37-0610-5
ACS800-37-0780-5
2 × NBRA-659 2 × (2 × SAFUR200F500)
ACS800-37-0870-5
ACS800-37-1160-5 3 × NBRA-659 3 × (2 × SAFUR200F500)
ACS800-37-0170-7
••• NBRA-669 2 × SAFUR200F500
ACS800-37-0540-7
690 V
ACS800-37-0790-7
2 × NBRA-669 2 × (2 × SAFUR200F500)
ACS800-37-0870-7
ACS800-37-1160-7 3 × NBRA-669 3 × (2 × SAFUR200F500)
Resistor braking
220
Chopper/Resistor combinations – Technical data

The following table contains the technical data of selected chopper/resistor
combinations.
Duty cycle Duty cycle
R Pbrmax Pcont Imax (10/60 s) (1/5 min) Airflow
UN Chopper(s) Resistors
(ohm) (kW) (kW) (A) (m3/h)
Pbr Irms Pbr Irms
(kW) (A) (kW) (A)
1 × NBRA-658 2 × SAFUR210F575 1.7 230 42 384 224 345 130 200 2500
1 × NBRA-659 2 × SAFUR180F460 1.2 353 54 545 287 444 167 257 2500
400 V
2 × NBRA-659 2 × (2 × SAFUR180F460) 1.2 706 108 545 575 444 333 257 5000
3 × NBRA-659 3 × (2 × SAFUR180F460) 1.2 1058 162 545 862 444 500 257 7500
1 × NBRA-658 2 × SAFUR125F500 2.0 268 36 408 192 237 111 137 2500
1 × NBRA-659 2 × SAFUR200F500 1.35 403 54 605 287 355 167 206 2500
500 V
2 × NBRA-659 2 × (2 × SAFUR200F500) 1.35 806 108 605 575 355 333 206 5000
3 × NBRA-659 3 × (2 × SAFUR200F500) 1.35 1208 162 605 862 355 500 206 7500
1 × NBRA-669 2 × SAFUR200F500 1.35 404 54 835 287 355 167 206 2500
690 V 2 × NBRA-669 2 × (2 × SAFUR200F500) 1.35 807 108 835 287 355 333 206 5000
3 × NBRA-669 3 × (2 × SAFUR200F500) 1.35 1211 162 835 575 355 500 206 7500
UN = Nominal voltage
R = Resistance of specified resistors (per chopper)
Pbrmax = Maximum short-term (1 min every 10 mins) braking power
Pcont = Maximum continuous braking power
Imax = Maximum peak current (per chopper)
Pbr = Braking power for the specified duty cycle
Irms = Corresponding RMS current (per chopper)
Airflow = Airflow required for cooling of chopper(s) and resistors
Resistor braking
221
Brake choppers – Technical data

The following table contains the technical data for the NBRA-6xx brake choppers.
Duty cycle Duty cycle
(10/60 s) (1/5 min)
Chopper Pbrmax Pcont Imax Irms R Ubr_on Ubr_off Airflow
UN
type (kW) (kW) (A) (A) (ohm) Pbr Irms Pbr Irms (V) (V) (m3/h)
(kW) (A) (kW) (A)
NBRA-658 230 70 384 109 1.7 230 355 230 355

400 V 674 660
NBRA-659 353 96 545 149 1.2 353 545 303 468
NBRA-658 268 81 380 101 2.15 268 331 268 331 660
500 V 811 795
NBRA-659 403 109 571 136 1.43 403 498 317 391
690 V NBRA-669 404 119 414 107 2.72 404 361 298 267 1120 1096
UN = Nominal voltage
Pbrmax = Maximum short-term (1 min every 10 mins) braking power
Pcont = Maximum continuous braking power
Imax = Maximum peak current
Irms = Corresponding RMS current
R = Recommended resistance
Pbr = Braking power for the specified duty cycle. Note: This value may be limited by Pbrmax.
Ubr_on = DC voltage at which chopper starts conducting
Ubr_off = DC voltage at which chopper stops conducting
Airflow = Airflow required for cooling of chopper
Brake resistors – Technical data

The following table contains the technical data for the resistors supplied by ABB.
UN R ER PRcont Airflow
Type
(V) (ohm) (kJ) (kW) (m3/h)
SAFUR125F500 500 4.0 3600 9.0
SAFUR210F575 575 3.4 4200 10.5

1000
SAFUR200F500 500 2.7 5400 13.5
SAFUR180F460 460 2.4 6000 15.0
U N = Nominal voltage
R = Resistance
ER = Short energy pulse that the resistor assembly will withstand each 400 seconds
PRcont = Continuous power (heat) dissipation of the resistor when placed correctly. Energy ER
dissipates in 400 seconds.
Airflow = Airflow required for cooling of one resistor
Resistor braking
222
Verifying the capacity of the braking equipment

1. Calculate the maximum power (Pmax) generated by the motor during braking.
2. Ensure the following condition is met:
Pbrmax > Pmax
The Pbrmax values specified in the technical data table above are for the reference braking cycle
(1 minute of braking, 9 minutes of rest). If the actual duty cycle does not correspond to the reference
cycle, the maximum allowed braking power Pbr must be used instead. In the technical data table,
Pbr is given for two additional braking cycles. See below for directions for calculating Pbr for other
braking cycles.
3. Check the resistors selection. The energy generated by the motor during a 400-
second period must not exceed the heat dissipation capacity ER.
If the ER value is not sufficient, it is possible to use a four-resistor assembly in which two standard
resistors are connected in parallel, two in series. The ER value of the four-resistor assembly is four
times the value specified for the standard resistor.
Custom resistors
Resistors other than the standard resistors can be used provided that:
• the resistance is not lower than with the standard resistors
WARNING! Never use a brake resistor with a resistance below the value specified
for the particular drive / brake chopper / resistor combination. The drive and the
chopper are not able to handle the overcurrent caused by the low resistance.
• the resistance does not restrict the braking capacity needed, i.e.,
2
UDC
Pmax <
R
where
Pmax maximum power generated by the motor during braking
UDC voltage over the resistor during braking, e.g.,
1.35 · 1.2 · 415 VDC (when supply voltage is 380 to 415 VAC),
1.35 · 1.2 · 500 VDC. (when supply voltage is 440 to 500 VAC) or
1.35 · 1.2 · 690 VDC (when supply voltage is 525 to 690 VAC).
R resistor resistance (ohm)
• the heat dissipation capacity (ER) of the resistors is sufficient for the application
(see step 3 above).
Resistor braking
223
Calculating the maximum braking power (Pbr)

• Braking energy transferred during any ten minute period must be less than or
equal to the energy transferred during the reference braking cycle.
• The braking power must not exceed the rated maximum value Pbrmax.
1. n × Pbr × t br < Pbrmax × 60 s

2. Pbr < Pbrmax
n = Number of braking pulses during

a ten minute period
Pbr = Maximum allowed braking power (kW).
tbr = Braking time (s)
Pbrmax = Maximum Braking Power
for a reference cycle (kW)
Example 1
Duration of a braking cycle is 30 minutes. The braking time is
15 minutes.
Result: If the braking time exceeds 10 minutes, the braking is considered
continuous. The allowed continuous braking power is 10% of the Maximum Braking
Power (Pbrmax).
Example 2
Duration of a braking cycle is three minutes. The braking time is
40 seconds.
Pbrmax × 60 s
1. Pbr < = 0.375 × Pbrmax
4 × 40 s
Pbr
Pbrmax
t
tbr 600 s
T = Duration of braking cycle
2. Pbr < Pbrmax O.K.
Result: The maximum allowed braking power for the cycle is 37 % of the rated value
given for the reference cycle.
Resistor braking
224
Example 3
Duration of a braking cycle is three minutes. The braking time is 10 seconds.
Pbrmax × 60 s
1. Pbr < = 1.5 · Pbrmax
4 × 10 s
Pbr
Pbrmax
t
tbr 600 s
T = Duration of the braking cycle
2. Pbr > Pbrmax Not allowed.
Result: The maximum allowed braking power for the cycle is equal to the Maximum
Braking Power (Pbrmax) given for the reference cycle.
Resistor braking
225
Custom resistor installation and wiring

Effective cooling of the resistors must be ensured.
WARNING! All materials near the brake resistors must be non-flammable. The
surface temperature of the resistors is high. The temperature of the air rising from
the resistors is hundreds of degrees Celsius. Protect the resistors against contact.
For resistor cable, use the type specified for drive input cabling (specified under
chapter Technical Data) so the input fuses will protect the resistor cable also. Two-
conductor shielded cable with the same cross-sectional area can alternatively be
used. The maximum length of the resistor cable is 10 m.
For protection against overheating, resistors with thermal circuit breakers (standard
in ABB resistors) should be used. The circuit breakers should be wired to the
ENABLE inputs of the brake choppers.
WARNING! The ENABLE input terminal blocks of the choppers are at intermediate
circuit potential when the supply unit of the ACS800-37 is running. This voltage is
extremely dangerous and may cause serious damage or injuries if the isolation level
and protection conditions for the thermal circuit breakers are not sufficient. The
normally-closed breakers should always be properly isolated (over 2.5 kV) and
shrouded against contact.
Note: For the ENABLE input wiring, use cable rated as follows:
• twisted pair (screened type recommended)
• rated operating voltage between a core and earth (U0): ≥ 750 V
• insulation test voltage > 2.5 kV
Resistor braking
226
The following is a wiring diagram example of the resistor connection.
Brake chopper
X1
R+ R– 1 2
1 2 3
R+ R–
t°
Brake resistor
Brake circuit commissioning

In the drive application program, overvoltage control of the drive must be disabled for
correct operation of the brake chopper. This has been done at the factory for units
with brake choppers.
Resistor braking
3AFE68557925 REV B EN
EFFECTIVE: 01.11.2005
ABB Oy ABB Inc.

AC Drives Automation Technologies
P.O. Box 184 Drives & Motors
FI-00381 HELSINKI 16250 West Glendale Drive
FINLAND New Berlin, WI 53151
Telephone +358 10 22 11 USA
Fax +358 10 22 22681 Telephone 262 785-3200
Internet http://www.abb.com 800-HELP-365
Fax 262 780-5135

Manual ABB

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Manual ABB

Uploaded by

Copyright:

Available Formats

ACS800

© 2005 ABB Oy. All Rights Reserved.

NEW (page 6): Safety / Installation and maintenance work

NEW (page 9): Safety / Operation

NEW (page 22): Terms and abbreviations

NEW/CHANGED (pages 40-41): Type code

NEW (pages 40-41): Type code

+Q968 Safe torque off (STO) with a safety relay

NEW (page 65): Emergency stop

NEW (page 67): Safe torque off

NEW (page 103): On-load checks

Check the correct operation of the emergency stop

NEW (page 103): On-load checks

• Ensure that the drive can be run and stopped

• Stop the drive (if running), switch the input power

• Check the STO circuit connections against the

Action Additional information

• Close the disconnector and switch the power on.

• Test the operation of the STO function when the

- Give a stop command for the drive (if running)

- Activate the STO circuit and give a start

- Ensure that the motor stays at standstill.

- Deactivate the STO circuit.

• Restart the drive and check that the motor runs

• Test the operation of the STO function when the

- Start the drive and ensure that the motor is

- Activate the STO circuit.

- Ensure that the motor stops and the drive trips.

- Reset the fault and try to start the drive.

- Ensure that the motor stays at standstill.

- Deactivate the STO circuit.

• Restart the drive and check that the motor runs

CHANGED (page 122): LEDs

NEW (page 136): Ambient conditions

Installation site altitude [...]

What this chapter contains

Usage of warnings and notes

Dangerous voltage warning warns of high voltages which can cause

General warning warns about conditions, other than those caused by

Installation and maintenance work

• Apply temporary grounding before working on the unit.

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

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

• Fastening the cabinet by riveting or welding is not recommended. However, if

• Ensure sufficient cooling of the unit.

• Some parts inside the drive cabinet, such as heatsinks of power

• The printed circuit boards contain components sensitive to electrostatic

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

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

• Do not install a drive equipped with an EMC (line) filter to an ungrounded

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

Fibre optic cables

• Do not activate automatic fault reset functions of the Standard Application

Permanent magnet motor drives

Installation and maintenance work

About this manual

Door switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Planning the electrical installation

Permanent magnet synchronous motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Motor control and I/O board (RMIO)

Installation checklist and start-up

Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Frame size 6×R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

About this manual

What this chapter contains

Common chapters for multiple products

Categorization according to the frame size

About this manual

Installation and commissioning flowchart

Plan the installation. Technical data

Unpack and check the units. Mechanical installation