ABB ACS800 Hardware Manual
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ABB ACS800 Hardware Manual

1.5 to 2000 kw inverter modules
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ACS800
Hardware Manual
ACS800-104 Inverter Modules
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Summary of Contents for ABB ACS800

  • Page 1 ACS800 Hardware Manual ACS800-104 Inverter Modules...
  • Page 3 ACS800-104 (1.5 to 2000 kW) Inverter Modules Hardware Manual 3AFE 64809032 REV B EFFECTIVE: 01.12.2003 © 2003 ABB Oy. All Rights Reserved.

  • Page 5: Table Of Contents

    Table of contents Table of contents Introduction to this manual What this chapter contains ............11 Compatibility .
  • Page 6 Mounting examples ............32 Single R8i module in a Rittal TS 8 cubicle .
  • Page 7 To which products this chapter applies ..........81 Note for the ACS800-02 with the enclosure extension and the ACS800-07 ....81 Note for external power supply .
  • Page 8 LEDs ............... . .92 ACS800-104 ordering information What this chapter contains .
  • Page 9 Circuit diagrams What this chapter contains ............121 Frame R2i to R5i .
  • Page 10 Frames R6i and R7i ............164 Module dimensions (excluding fan) .

  • Page 11: Introduction To This Manual

    Introduction to this manual What this chapter contains This chapter gives the basic information on the manual. Compatibility The manual is compatible with the ACS800-104 inverter modules intended for user- defined cabinet installations. Safety instructions Follow all safety instructions delivered with the drive.

  • Page 12: Related Publications

    [English]) • ACS 800 MultiDrive Modules; Planning the Cabinet Installation (3AFE 64783531 [English]) • ACS800-304 and ACS800-704 Diode Supply Units User’s Manual (3AFE 64494023 [English]) • ACS 800 Product Reference (3AFE 64813340 [English]). Contains descriptions of ACS 800 drive products and information on generic options •...

  • Page 13: Terms And Abbreviations

    Abbreviation Common mode filtering. DDCS Distributed Drives Communication System; a protocol used in optical fibre communication inside and between ABB drives. Drive unit See Inverter unit. Diode supply unit (consisting of one or more diode supply modules). Direct Torque Control.
  • Page 14 Introduction to this manual...

  • Page 15: Hardware Description

    What this chapter contains This chapter describes a typical drive system and the hardware of the inverter modules. The information is valid for all ACS800-104 inverter modules. Typical drive system The diagram below depicts a common DC bus drive system.

  • Page 16: Inverter Module Hardware

    Inverter module hardware The ACS800-104 range of inverter modules contains components for building the inverter unit(s) of a common DC bus system drive. The chapter ACS800-104 ordering information lists the order codes of the inverter module components. See also the...

  • Page 17: Cabinet Layout

    Cabinet construction. Drawings of mounting accessories for both vertical and inclined mounting, suitable for common cabinet systems, are shown under Dimensional drawings. (The plates for inclined mounting can be ordered from ABB.) Vertical mounting Inclined mounting Cool area Hot area...

  • Page 18: Frames R6I And R7I

    Frames R6i and R7i Frame R6i and R7i modules have the DC input connection at the top of the module, while the AC connection is at the bottom. The DC voltage is connected to the input busbars either through fuses only or through a switch fuse with charging control circuitry.

  • Page 19: Frame R8I And Multiples

    (400 V) source. Internal du/dt filters are also available. For information on whether du/dt filtering is necessary, see the document ACS800 MultiDrive; Planning the Electrical Installation (3AFE 64783742 [English]). (du/dt filtering must be selected if a common motor terminal cubicle is used.

  • Page 20: Module Layout

    Module layout Item Explanation DC (input) connections Output busbars. To be aligned with the quick connector socket mounted in the cubicle. Direct connection of cables without using the quick connector is also possible. Fibre optic connectors of the AINT board. Connected to the RDCU drive control unit (via an NPBU branching unit in case of parallel inverter modules).

  • Page 21: Cabinet Layout

    Cabinet layout Inverter modules can be installed side by side. The DC fuses and/or switch fuse are to be installed above the modules. The control electronics (RDCU control unit, PPCS branching unit [for parallel modules only], relays and other auxiliary voltage equipment) are to be installed in a separate cubicle.

  • Page 22: Control Interfaces

    Control interfaces The following diagram shows the control interfaces and I/O options of the inverter unit. The front cover of frame R5i has a platform for the CDP 312R control panel; frames R2i to R4i require an additional platform kit if the panel needs to be mounted on the module.

  • Page 23: Type Code

    (common for the whole product series), followed by descriptive digits. The option codes are separated by plus signs. The main selections are described below. Not all options are necessarily available for all types. For more information, contact your local ABB representative. Basic code Digit no.
  • Page 24 Hardware description...

  • Page 25: Cabinet Construction

    Cabinet construction What this chapter contains This chapter contains instructions for constructing the cabinet for ACS800-104 inverter units. Also refer to the document ACS800 MultiDrive Modules; Planning the Cabinet Installation (3AFE 64783572 [English]). Cabinet construction...

  • Page 26: Frame R2I To R5I

    Frame R2i to R5i Guiding the cooling air flow The hot air from an inverter module must not be allowed to enter another module. In a cubicle with multiple modules, a practical way of achieving this is to install a mounting plate to separate the cool area (at the front part of the cubicle) from the hot area (back part).
  • Page 27 To save vertical space, the inverter modules can be mounted by their flanges in an inclined position as exemplified below. SIDE VIEW Cool area Hot area Inverter modules Mounting plates Air baffle The chapter Dimensional drawings presents mounting plates for vertical and inclined mounting positions.

  • Page 28: Layout Examples

    Layout examples The drawing below is a front view of a cubicle with three R2i modules installed on top of each other. DC switch fuse DC fuses du/dt filter Inverter modules Motor cable entries...
  • Page 29 This drawing is a side view of three R3i modules in a 400 mm-wide cubicle. DC bus DC fuse bases Airflow guides Inverter modules Motor cable entries...

  • Page 30: Frames R6I And R7I

    Frames R6i and R7i The module can be installed in the cabinet using the optional mounting plate (code 64138375) and a separate air baffle. Alternatively, a combined mounting plate/air baffle can be constructed. The fixing points are shown in the cabinet layout examples below.

  • Page 31: Installation Without Mounting Plate 64138375

    Installation without mounting plate 64138375 The module is fastened to the rear wall with two M8 screws, and to a combined mounting plate/air baffle with four M6 screws. The cooling fan is also fixed to the plate which has to be strong enough to carry the weight of the module. A suitable design for the mounting plate/air baffle is shown in Dimensional drawings.

  • Page 32: Frame R8I And Multiples

    Frame R8i and multiples General See the chapter Technical data for module-specific cooling requirements. Cooling In a typical cabinet construction, the air inlet is at the bottom of the cabinet, while the outlet is at the top, ideally on the roof. The inlet may be filtered. Note: Do not install a filter in the air outlet.

  • Page 33: Single R8I Module In A Rittal Ts 8 Cubicle

    Single R8i module in a Rittal TS 8 cubicle...

  • Page 38: Two R8I Modules In A Rittal Ts 8 Cubicle

    Two R8i modules in a Rittal TS 8 cubicle...

  • Page 43: Three R8I Modules In A Rittal Ts 8 Cabinet

    Three R8i modules in a Rittal TS 8 cabinet...

  • Page 46: Three R8I Modules Side By Side

    Three R8i modules side by side...

  • Page 49: Electrical Installation

    • Maximum long-term tensile load: 1 N • Flexing: Max. 1000 cycles ABB drive products in general utilise 5 and 10 MBd (megabaud) optical components from Agilent Technologies’ (Hewlett-Packard) Versatile Link range. Please note that the optical component type is not directly related to the actual communication speed.

  • Page 50: Checking The Insulation Of The Assembly

    SpecTran Corporation. Checking the insulation of the assembly Every ACS800-104 inverter module has been tested for insulation between the main circuit and the chassis (2500 V rms 50 Hz for 1 second) at the factory. Therefore, do not make any voltage tolerance or insulation resistance tests (e.g.

  • Page 51: Power Connections - Frame R2I To R5I

    Power connections – Frame R2i to R5i Diagram Inverter module INPUT OUTPUT UDC+ UDC- U1 V1 W1 Motor 1) 360 degrees grounding Grounding of the motor cable shield at the motor end For minimum radio frequency interference: • ground the cable shield 360 degrees at the lead-through of the motor terminal box 2) Use a separate grounding cable if the 360 degrees grounding...

  • Page 52: Conductor Stripping Lengths

    Conductor stripping lengths Strip the conductor ends as follows to fit them inside the power cable connection terminals. Stripping length Frame size R2i, R3i 0.39 R4i, R5i 0.63 Connection box kit The inverter module is supplied with a connection box kit containing the following items: •...

  • Page 53: Frame R2I To R4I Power Connections

    Cover Cable clamps Back plate Frame R2i to R4i power connections Frame R3i pictured. Item No. Information Connect to PE busbar of cabinet. UDC+ UDC– 2…4 Prevention of unexpected start (optional). See also the chapter Circuit diagrams. L (95…265 V AC). Voltage must be ON for the inverter to start.

  • Page 54: Frame R5I Power Connections

    Frame R5i power connections Item No. Information Connect to PE busbar of cabinet. UDC+ UDC– 2…4 Prevention of unexpected start (optional). See also the chapter Circuit diagrams. L (95…265 V AC). Voltage must be ON for the inverter to start. Strip off the outer sheathing of the cable at the clamp.

  • Page 55: Power Connections - Frames R6I And R7I

    Power connections – Frames R6i and R7i Diagram Inverter module INPUT OUTPUT UDC+ UDC- Cabinet Note: Charging circuit configuration may differ from type to type. See the chapter Circuit diagrams. NCHM-01 Switch fuse controller Motor *Use a separate grounding cable if the conductivity Grounding of the motor cable shield at the motor end of the cable shield is less than 50% of the For minimum radio frequency interference:...

  • Page 56: Dc And Motor Connections

    DC and motor connections DC input L+ (UDC+) L– (UDC–) Motor output Charging circuit Installing a switch fuse between the inverter module(s) and the DC link necessitates a charging circuit. In frame R6i units, the charging circuit consists of charging resistors and a contactor;...

  • Page 57: Installation Of Common Mode Filters

    Installation of common mode filters The following diagram shows how the common mode filter (consisting of three toroidal cores) is installed on the output cable. In order to provide thermal insulation for conductors, Tie conductors tightly together using wrap cables inside toroid rings with silicon rubber tape non-conductive electrical tape plus included.

  • Page 58: Power Connections - Frame R8I And Multiples

    Power connections – Frame R8i and multiples See also the document ACS800 MultiDrive; Planning the Electrical Installation (3AFE 64783742 [English]). Wiring diagram Inverter module INPUT OUTPUT UDC+ UDC- Common mode filtering (optional) ASFC-01C Switch fuse controller Motor DC connection The DC connection busbars are located at the top of the module. See the dimensional diagrams for the exact location.

  • Page 59: Charging Circuit

    Charging circuit Installing a switch fuse between the inverter module(s) and the DC link necessitates a charging circuit. The charging circuit contains two resistors per inverter module and a switch fuse controller (type ASFC-01C). The resistors and the controller are included in the switch fuse kits.

  • Page 60: Direct Motor Cabling

    Direct motor cabling The diagram below shows the connection of the motor when the inverter unit consists of one inverter module only. Inverter unit cubicle If a common motor terminal cubicle is not used, all the inverter modules in a parallel configuration (2×R8i, 3×R8i, etc.) are to be cabled separately to the motor as shown in the diagram below.
  • Page 61 WARNING! The cabling from all inverter modules to the motor must be physically identical considering cable type, cross-sectional area, and length. For example, “jumpering” the cables from one inverter module to another (and then to the motor) is not allowed. Inverter unit cubicle Inverter unit cubicle...

  • Page 62: Common Motor Terminal Cubicle

    Common motor terminal cubicle Instead of direct cabling from each inverter module to the motor, it is also possible to build a common motor terminal cubicle. WARNING! If a common motor terminal cubicle is constructed, the inverter modules must be equipped with the +E205 option (internal du/dt filters). Note that the distance from both modules to the common output should be of roughly equal length.

  • Page 63: Control Connections

    Control connections Frame R2i to R5i These inverter modules have a built-in RMIO (Motor control and I/O) board. For descriptions of the terminals, see the chapter Motor control and I/O board (RMIO). Frame R2i to R4i (R3i pictured) Detachable I/O terminals (pull upwards) The control cable connection terminals are exposed when the RMIO X39 for control...

  • Page 64: Frame R5I

    Frame R5i Optional module 1 Optional module 2 RMIO X39 for control panel cable DDCS communication option module 3: RDCO Install shroud (included) on the Control cable relay outputs if voltage at the grounding: see terminals exceeds 50 V AC degrees grounding of I/O cables page...

  • Page 65: Frame R6I, R7I, R8I And Multiples

    Frame R6i, R7i, R8i and multiples Inverter units consisting of frame R6i, R7i and R8i inverter modules employ a separate control unit, RDCU-02C, containing the RMIO board. For the terminals of the RMIO board, see the chapter Motor control and I/O board (RMIO).

  • Page 66: R6I/R7I Connectors

    R6i/R7i connectors The following picture shows the fibre optic connectors V41 and V42 on the NINT board as well as the NGPS connection (optional). NGPS X1 NINT V42 NINT V41 Terminal no. Information 1…3 Prevention of unexpected start (optional). See also the chapter Circuit diagrams.

  • Page 67: R8I Connectors

    R8i connectors The fibre optic connectors (for connections to both the RDCU and the ASFC boards) on the AINT board of the inverter module are accessible through an opening on the front. Optical cable routing Access to fibre optic connectors of AINT board If the inverter module is equipped with the Prevention of unexpected start option (+Q950), or not equipped with a speed-controlled fan (option +C126), the necessary...

  • Page 68: Degrees Grounding Of I/O Cables

    360 degrees grounding of I/O cables Insulation Double shielded cable Single shielded cable When the outer surface of the shield is covered with non-conductive material • Strip the cable carefully (do not cut the grounding wire and the shield) • Turn the shield inside out to expose the conductive surface. •...

  • Page 69: Cabling Of I/O And Fieldbus Modules

    Cabling of I/O and fieldbus modules Module Keep as short as possible Shield Note: The RDIO module does not include a terminal for cable shield grounding. Ground the pair cable shields here. Pulse encoder module cabling As short as possible Note 1: If the encoder is of unisolated type, ground the encoder cable at the drive end only.

  • Page 70: Installation Of Optional Modules And Pc

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

  • Page 71: Installation Of Nlmd-01 Led Monitoring Display

    Installation of NLMD-01 LED Monitoring Display Mechanical installation 64152955...

  • Page 72: Wiring

    Wiring Control panel with monitoring display Monitoring Display NLMD-01 Control Panel CDP 312R Panel Interface ADPI-01 RMIO Monitoring display only RMIO NLMD-01...

  • Page 73: Earthing

    Earthing Each NLMD-01 board is to be individually earthed. The earthing wires are included in the control panel platform and LED display kits. NLMD-01 DIN 7981 F 3,5×6,5 TORX, St/Zn NLMD-01 NLMD-01 ADPI-01...

  • Page 75: External +24 V Power Supply For The Rmio Board

    External +24 V power supply for the RMIO board What this chapter contains This chapter describes how to connect external +24 V power supply for the RMIO board. When to use External +24 V power supply for the RMIO board is recommended if •...

  • Page 76: Connecting +24 V External Power Supply

    Connecting +24 V external power supply 1. Break off the tab covering the +24 VDC power input connector with pliers. 2. Lift the connector upwards. 3. Disconnect the wires from the connector (keep the connector for later use). 4. Isolate the ends of the wires individually with insulating tape. 5.
  • Page 77 External +24 V power supply for the RMIO board...
  • Page 78 External +24 V power supply for the RMIO board...

  • Page 79: Installation Checklist

    Installation checklist Checklist Check the mechanical and electrical installation of the drive before start-up. Go through the checklist below together with another person. Check MECHANICAL INSTALLATION The ambient operating conditions are allowed. (See Technical data.) The unit is properly fastened on a non-flammable base. (See Cabinet construction, and separate document ACS 800 MultiDrive Modules;...
  • Page 80 Installation checklist...

  • Page 81: Motor Control And I/O Board (Rmio)

    • specifications of the inputs and outputs of the board. To which products this chapter applies This chapter applies to ACS800 units which employ the RMIO board. Note for the ACS800-02 with the enclosure extension and the ACS800-07 The terminals of the RMIO board are wired to optional terminal block X2 (if present).

  • Page 82: External Control Connections (Non-Us)

    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. Terminal block size: VREF- Reference voltage -10 VDC, 1 kohm <...

  • Page 83: External Control Connections (Us)

    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. Terminal block size: VREF- Reference voltage -10 VDC, 1 kohm <...

  • Page 84: Rmio Board Specifications

    RMIO board specifications Analogue inputs With Standard Application Program two programmable differential current inputs (0 mA / 4 mA ... 20 mA, R = 100 ohm) and one programmable differential voltage input (-10 V / 0 V / 2 V ... +10 V, R >...

  • Page 85: Relay Outputs

    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...
  • Page 86 Isolation and grounding diagram (Test voltage: 500 V AC) VREF- AGND VREF+ AGND AI1+ Common mode AI1- voltage between AI2+ channels ±15 V AI2- AI3+ AI3- AO1+ AO1- AO2+ AO2- Jumper J1 settings: DGND1 All digital inputs share a common ground.

  • Page 87: Maintenance

    Maintenance What this chapter contains This chapter contains preventive maintenance instructions, and a description of the LEDs of the drive. Safety instructions Only a qualified electrician is allowed to perform the maintenance. Before starting work on the drive system, • isolate the drive system from the main supply •...

  • Page 88: Maintenance Intervals

    Maintenance intervals This table lists the routine maintenance intervals recommended by ABB. Maintenance Interval Instructions Capacitor reforming Every year when stored Capacitor reforming. Depending on the dustiness of Heatsink temperature check the environment, every 6 to 12 See Heatsinks. and cleaning months Cabinet air filter check;...

  • Page 89: Cooling Fans

    If the drive is operated in a critical part of a process, fan replacement is recommended once these symptoms start appearing. Replacement fans are available from ABB. Do not use other than ABB-specified spare parts.

  • Page 90: Fan Replacement (R5I)

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

  • Page 91: Fan Replacement (R8I)

    Fan replacement (R8i) 1. Read and repeat the steps in the safety instructions above. 2. Open the inverter cubicle doors. 3. Disconnect the fan wiring plug (1). 4. Remove the locking screws (2). 5. Pull the fan out along its sliding rails (3). 6.

  • Page 92: Power Connections (R8I)

    It is not possible to predict a capacitor failure. Capacitor failure is usually followed by a mains fuse failure or a fault trip. Contact ABB if capacitor failure is suspected. Replacements are available from ABB. Do not use other than ABB-specified spare parts.

  • Page 93: Acs800-104 Ordering Information

    ACS800-104 ordering information What this chapter contains This chapter lists the components and accessories specific to the ACS800-104 inverter module range. See the ACS800 Product Reference (3AFE 64813340 [English]) for generic equipment for the ACS 800 product family such as control panels, I/O options, application programs and PC tools.
  • Page 94 = 690 V (525/575/600/660/690 V) ACS800-104-0011-7 64771116 64772473 ACS800-104-0016-7 64772074 64772481 ACS800-104-0020-7 18.5 64772082 64772490 ACS800-104-0025-7 64772091 64772503 ACS800-104-0030-7 64772104 64772511 ACS800-104-0040-7 64772171 64772520 ACS800-104-0050-7 64772325 64772538 ACS800-104-0060-7 64772376 64772546 ACS800-104-0070-7 68260515 68260540 ACS800-104-0100-7 68260523 68260558 ACS800-104-0120-7 68260531 68260566 PDM-256538 ACS800-104 ordering information...

  • Page 95: Frame Size R8I And Multiples

    +E205: du/dt filtering (required for 690 V modules, and parallel-connected modules) +Q950: Prevention of unexpected start (factory-installed in parallel-connected modules) (for more information, see the document ACS800 MultiDrive; Planning the Electrical Installation [3AFE 64783742, English]). Inverter modules (R8i and multiples)

  • Page 96: Dc Fuses And Fuse Bases; Dc Switch Fuses

    The tables below specify the DC fuses, DC fuse bases, switch fuse kits, and charging circuit fuses for the ACS800-104 inverter units. DC fuses and fuse bases/Switch fuse kits for inverter modules Switch fuse kit...
  • Page 97 64808842 1–Switch Fuse (OESL630/32D02) • 2–Resistor (ZRF 30×165) • 1–Switch fuse controller (ASFC-01C) 64808851 1–Switch Fuse (OESL630/32D04) • 4–Resistor (ZRF 30×165) • 1–Switch fuse controller (ASFC-01C) 64808877 1–Switch Fuse (OESL630/32D06) • 6–Resistor (ZRF 30×165) • 1–Switch fuse controller (ASFC-01C) ACS800-104 ordering information...
  • Page 98 0610-5 170M OFAX 2×125A 0770-3 0910-5 09838767 58065749 1564 660V 00S2L 690V 1030-3 1210-5 1540-3 1820-5 2050-3 2430-5 170M OFAX 2×125A 09838767 58065749 1564 660V 00S2L 690V 170M OFAX 2×125A 2320-7 10032601 58065749 2690 1000V 00S2L 690V ACS800-104 ordering information...

  • Page 99: Inclined Mounting Plates For R2I To R5I Modules

    Cooling fans for R6i and R7i modules Information Order code Fan (230 VAC) Fan type: G2E140-P151-09. Connection cable length: 1.5 m (5 ft). 64114158 Fan type: G2E140-AI32-ABB. Connection cable length: 1.5 m (5 ft). 64114191 Fan (115 VAC) Use a separate air baffle. 64138375 Mounting plate...

  • Page 100: Installation Parts For R8I Modules

    Installation parts for R8i modules The following tables list the R8i installation parts available from ABB. Also refer to the drawings in the chapters Cabinet construction Dimensional drawings. Quick connector chassis socket kits The chassis socket part of the quick connector is to be mounted on the rear pillars of the cubicle.

  • Page 101: Dc Busbar Kits

    Connecting 4 pcs Busbar busbars from Single R8i 2 pcs Holder for 68256747 switch fuse module (2-pole common mode filters (OESL) to DC switch fuse) 5 pcs Support insulator input of module ACS800-104 ordering information...
  • Page 102 15 pcs Support switch fuse) insulator 1 + 2 R8i 12 pcs Busbar modules in 6 pcs Holder for adjacent Rittal common mode filters 68260752 TS 8 cubicles 15 pcs Support (6-pole switch insulator fuse) ACS800-104 ordering information...

  • Page 103: Upper And Lower Guides

    2 pcs Air baffle 68283027 1 pcs EMC sealing, TS 8 cubicle conductive (comes in 2 pieces) 2 pcs Lower guide Two R8i 2 pcs Upper guide modules side by 68259517 2 pcs Upper guide, rear side 2 pcs Crossmember ACS800-104 ordering information...
  • Page 104 3 pcs Upper guide modules side by 3 pcs Upper guide, rear 68259541 1 pcs Crossmember, front side 1 pcs Crossmember, rear 1 + 2 R8i modules in 68283027 + 68283035 68260833 adjacent Rittal TS 8 cubicles ACS800-104 ordering information...

  • Page 105: Cabinet Ventilation Kits

    471 × 504 mm kit, unfiltered (18.54” × 19.84”) 800 mm wide cubicle. 1 pc Grille (metallic) 68259827 Aperture size: 671 × 522 mm (26.42“ × 20.54”) 400 + 600 mm 68239478 + 68239460 68260817 wide cubicles ACS800-104 ordering information...
  • Page 106 (metallic) cubicle. 1 pc Filter mat (Luftfilter airTex G150) 68259797 Aperture size: 1 pc Grille, outer 671 × 522 mm (plastic) (26.42“ × 20.54”) 2 pcs Fastener 400 + 800 mm 68239443 + 68239451 68260795 wide cubicles ACS800-104 ordering information...

  • Page 107: Ppcs Branching Units For N×R8I Inverter Units

    *Check availability with ABB Output (du/dt) filters for frame R2i to R7i inverter modules For information on the usage of output (du/dt) filters, see the document ACS800 MultiDrive; Planning the Electrical Installation (3AFE 64783742, English). Output (du/dt) filters for inverter modules...
  • Page 108 ACS800-104 ordering information...

  • Page 109: Technical Data

    Technical data What this chapter contains This chapter contains the technical data for the ACS800-104 inverter modules and associated optional equipment. IEC ratings Frame R2i to R7i Nominal ratings No-overload use Light-overload use Heavy-duty use Frame Inverter module type size cont.max...

  • Page 110: Frame R8I And Multiples

    Nominal ratings No-overload use Light-overload use Heavy-duty use Frame Inverter module type size cont.max cont.max ACS800-104-0016-7 ACS800-104-0020-7 18.5 ACS800-104-0025-7 18.5 ACS800-104-0030-7 18.5 ACS800-104-0040-7 ACS800-104-0050-7 ACS800-104-0060-7 ACS800-104-0070-7 ACS800-104-0100-7 ACS800-104-0120-7 Frame R8i and multiples No-overload Light-overload Nominal ratings Heavy-duty use Frame Inverter modules...

  • Page 111: Symbols

    In altitudes from 1000 to 4000 m (3300 to 13123 ft) above sea level, the derating is 1% for every 100 m (328 ft). For a more accurate derating, use the DriveSize PC tool. If the installation site is higher than 2000 m (6600 ft) above sea level, please contact your local ABB distributor or office for further information.

  • Page 112: Dimensions, Noise, Dc Capacitance

    Inverter module/unit Frame level capacitance type size mm (in.) mm (in.) mm (in.) kg (lbs) µF = 400 V ACS800-104-0003-3 401 (15.79) 165 (6.50) *193 (7.60) 9 (20) ACS800-104-0004-3 401 (15.79) 165 (6.50) *193 (7.60) 9 (20) ACS800-104-0005-3 401 (15.79) 165 (6.50)
  • Page 113 Depth Weight Inverter module/unit Frame level capacitance type size mm (in.) mm (in.) mm (in.) kg (lbs) µF ACS800-104-0610-5 1×R8i 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 14350 ACS800-104-0910-5 2×R8i ***1397 (55.00) ***245 (9.65) ***596 (23.46) ***150 (330) 24600 ACS800-104-1210-5 2×R8i...

  • Page 114: Power Loss And Cooling Characteristics

    Luftfilter/ unfiltered Luftfilter/ flow airTex G150 airTex G150 W (Btu/h) /h (ft /min) = 400 V ACS800-104-0003-3 80 (280) 35 (21) 100 (16) 200 (31) 160 (25) 320 (50) ACS800-104-0004-3 100 (340) 35 (21) 100 (16) 200 (31)
  • Page 115 Luftfilter/ unfiltered Luftfilter/ flow airTex G150 airTex G150 W (Btu/h) /h (ft /min) ACS800-104-0260-5 1×R8i 3300 (11300) 1280 (750) 575 (90) 1150 (180) 920 (140) 1840 (290) ACS800-104-0320-5 1×R8i 3900 (13300) 1280 (750) 575 (90)

  • Page 116: Cable Terminals

    Cable terminals DC input and motor cable terminal sizes, accepted cable diameters and tightening torques are given below UDC+, UDC–, U2, V2, W2 Earthing PE Frame Maximum Tightening Max. wire size Cable Ø Tightening torque size wire size torque lbf.ft lbf.ft 6 AWG 0.83...

  • Page 117: Efficiency

    Maximum recommended Sizing method Max. motor cable length motor cable length DTC control Scalar control according to I and I R2i to R3: 100 m (328 ft) R2i: 150 m (492 ft) according to I R4i to R5i: 300 m (984 ft) R3i to R5i: 300 m (984 ft) cont.max ambient temperatures below...

  • Page 118: Materials

    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.

  • Page 119: Auxiliary Power Consumptions

    – 0.08 – NCHM-21 – NCHM-22 – – 50/60 0.16 6.0 (1/2 cycle) NGPS-01 – 0.32 6.0 (1/2 cycle) NPBU-42 – – 0.235 RDCU-02 – – 0.25 Cooling fans Frame start Type size V AC G2E140-P151-09 G2E140-AI32-ABB D2D160-BE02-11 Technical data...
  • Page 120 Technical data...

  • Page 121: Circuit Diagrams

    Circuit diagrams What this chapter contains This chapter contains the block diagrams of the ACS800-104 inverter modules, as well as example connection diagrams for the whole inverter unit. Circuit diagrams...

  • Page 122: Frame R2I To R5I

    Frame R2i to R5i R2i/R3i – Block diagram...

  • Page 123: R4I - Block Diagram

    R4i – Block diagram...

  • Page 124: R5I - Block Diagram

    R5i – Block diagram...

  • Page 125: Example - Three Frame R2I To R5I Inverter Units

    Example – Three frame R2i to R5i inverter units...

  • Page 126: Frame R6I And R7I

    Frame R6i and R7i Connection diagram...

  • Page 127: R6I - Charging Circuit

    R6i – Charging circuit...

  • Page 128: R7I - Charging Circuit

    R7i – Charging circuit...

  • Page 129: Frame R8I And Multiples

    Frame R8i and multiples R8i – Internal diagram The diagram depicts an R8i module with optional speed-controlled fan.

  • Page 130: Charging Circuit

    Charging circuit...

  • Page 131: 2×R8I

    2×R8i...

  • Page 132: 3×R8I

    3×R8i...

  • Page 133: I/O And Control

    I/O and control...

  • Page 134: 2×R8I

    2×R8i...

  • Page 135: Cooling Fan Control (Inverter Modules Without Optional Speed-Controlled Fan)

    Cooling fan control (inverter modules without optional speed-controlled fan) Auxiliary voltage distribution...

  • Page 137: 2×R8I

    2×R8i...

  • Page 138: Example - Emergency Stop (Category 1)

    Example – Emergency stop (Category 1)

  • Page 139: Example - Prevention Of Unexpected Start

    Example – Prevention of unexpected start...

  • Page 141: Dimensional Drawings

    Dimensional drawings What this chapter contains This chapter contains dimensional drawings of the ACS800-104 inverter modules as well as auxiliary components and mounting accessories. Dimensional drawings...

  • Page 142: Frame R2I

    Frame R2i Module dimensions...

  • Page 143: Mounting Plate (Vertical)

    Mounting plate (vertical)

  • Page 144: Airflow Guide For Vertical Mounting

    Airflow guide for vertical mounting...

  • Page 146: Mounting Plate (Inclined)

    Mounting plate (inclined)

  • Page 147: Frame R3I

    Frame R3i Module dimensions...

  • Page 148: Mounting Plate (Vertical)

    Mounting plate (vertical)

  • Page 149: Airflow Guide For Vertical Mounting

    Airflow guide for vertical mounting...

  • Page 151: Mounting Plate (Inclined)

    Mounting plate (inclined)

  • Page 152: Frame R4I

    Frame R4i Module dimensions...

  • Page 153: Mounting Plate (Vertical)

    Mounting plate (vertical)

  • Page 154: Airflow Guide For Vertical Mounting

    Airflow guide for vertical mounting...

  • Page 156: Mounting Plate (Inclined)

    Mounting plate (inclined)

  • Page 158: Frame R5I

    Frame R5i Module dimensions...

  • Page 159: Mounting Plate (Vertical)

    Mounting plate (vertical)

  • Page 160: Airflow Guide For Vertical Mounting

    Airflow guide for vertical mounting...

  • Page 162: Mounting Plate (Inclined)

    Mounting plate (inclined)

  • Page 164: Frames R6I And R7I

    Frames R6i and R7i Module dimensions (excluding fan)

  • Page 165: Main Dimensions And Clearances Of Module (Including Fan)

    Main dimensions and clearances of module (including fan) Wall...

  • Page 166: Cooling Fan Dimensions

    Cooling fan dimensions...

  • Page 167: Mounting Plate (Kit #64138375)

    Mounting plate (Kit #64138375)

  • Page 169: Combined Mounting Plate/Air Baffle

    Combined mounting plate/air baffle...

  • Page 170: Frame R8I

    Frame R8i Module dimensions...

  • Page 172: Quick Connector Chassis Socket Kits

    Quick connector chassis socket kits Kit #68239427...

  • Page 173: Kit #68239435

    Kit #68239435...

  • Page 174: Kit #68242231

    Kit #68242231...

  • Page 175: Module Guiding Parts

    Module guiding parts Upper guide...

  • Page 177: Rear Upper Guide

    Rear upper guide...

  • Page 178: Lower Guide

    Lower guide...

  • Page 180: Crossmembers

    Crossmembers Rittal TS 8, 400 mm (included in kit #68256836)
  • Page 182 Rittal TS 8, 600 mm (included in kit #68259517)

  • Page 184: Front Crossmember, 3 Modules Side By Side (Included In Kit #68259541)

    Front crossmember, 3 modules side by side (included in kit #68259541)

  • Page 186: Rear Crossmember, 3 Modules Side By Side (Included In Kit #68259541)

    Rear crossmember, 3 modules side by side (included in kit #68259541)

  • Page 187: Fuse/Fuse Switch Mounting Plates

    Fuse/Fuse switch mounting plates Mounting plate, single R8i mod. in a Rittal TS 8 cubicle (included in kit #68283027)

  • Page 189: Mounting Plate, Two R8I Modules In A Rittal Ts 8 Cubicle (Included In Kit #68283035)

    Mounting plate, two R8i modules in a Rittal TS 8 cubicle (included in kit #68283035)

  • Page 191: Air Baffles

    Air baffles Air baffle, single R8i module in a Rittal TS 8 cubicle (included in kit #68283027)

  • Page 193: Air Baffle, Two R8I Modules In A Rittal Ts 8 Cubicle (Included In Kit #68283035)

    Air baffle, two R8i modules in a Rittal TS 8 cubicle (included in kit #68283035)

  • Page 195: Module Extraction/Insertion Ramp

    Module extraction/insertion ramp This example design of a module extraction/insertion ramp is for a lifting height of 50 mm, and should be redesigned for other heights.

  • Page 197: Control Electronics

    Control electronics RDCU-02(C) control unit...

  • Page 198: Npbu-42C Branching Unit

    NPBU-42C branching unit N P B U - 4 2 N P B U - 4 2 P P C S B R A N C H I N G U N I T , 4 C H V 1 3 5 C H 4 V 1 3 4 R X D...

  • Page 199: Apbu-44C Branching Unit

    APBU-44C branching unit A P B U - 4 4 C B O A R D A P B U - 4 4 C V 2 1 C H 1 C H 5 V 2 2 V 2 3 C H 2 C H 6 V 2 4 V 2 5...

  • Page 200: Fuse Bases

    Fuse bases OFAX series Ø J EN 50023 OFAX_A_ OFAX_P_ OFAX_S_ ØJ OFAX 00_ 25.5 OFAX 1_ 59.5 114.5 169.5 64 140 10.5 OFAX 2_ 69.5 134.5 199.5 84 160 10.5 OFAX 3_ 60 141.5 223 164 10.5 81.5 142.5 OFAX 1S_: 119 OFAX 1S_: 133 Ø...

  • Page 201: Ofasa3

    OFASA3...

  • Page 202: Switch Fuses, Charging Control Units

    Switch fuses, charging control units OESA00D2PL OZXK2 auxiliary contacts...

  • Page 203: Oesl 630/32D02

    OESL 630/32D02...

  • Page 204: Oesl 630/32D04

    OESL 630/32D04...

  • Page 205: Oesl 630/32D06

    OESL 630/32D06...

  • Page 206: Asfc-21C Switch Fuse Controller

    ASFC-21C switch fuse controller 6 5 . 5 2 3 0 V 1 1 5 V L S O L N S O L A S F C - 0 1 C S W I T C H F U S E C O N T R O L L E R 1 5 V A U X 2...

  • Page 207: Nchm-11/21 Charging Control Unit

    NCHM-11/21 charging control unit 6 7 . 1 1 5 7 . 5 F U S E T 3 1 5 m A U R - U R + F U S E S W I T C H F R O M C H A R G I N G S O L E N O I D R E S I S T O R...

  • Page 208: Diverse

    Diverse Output (du/dt) filters Common mode filter toroids PDM-58368-B...
  • Page 210 ABB Oy AC Drives P.O. Box 184 FIN-00381 HELSINKI FINLAND Telephone +358 10 22 211 Telefax +358 10 22 22681 Internet http://www.abb.com...

This manual is also suitable for:

Acs800-104

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