Acs800 207lc HW Manual Rev A

ACS800
Hardware Manual
ACS800-207LC IGBT Supply Units
ACS800 liquid-cooled multidrive manuals
GENERAL DRIVE MANUALS
1) Code (EN)
ACS800 Liquid-cooled Multidrive and Multidrive Modules
Safety Instructions
3AFE68715318
ACS800 Liquid-cooled Multidrive and Multidrive Modules
Planning the Electrical Installation
3AFE68715423
ACS800 Liquid-cooled Multidrive Modules Planning the
Cabinet Installation
3AFE68818559
ACS800 Liquid-cooled Multidrive Mechanical Installation 3AFE68715466
SUPPLY UNIT HARDWARE AND FIRMWARE MANUALS
2)
ACS800-307LC, -507LC, -1107LC, -1207LC Diode Supply
Unit Hardware Manual
3AFE68715474
ACS800 Liquid-cooled Diode Supply Control Program
Firmware Manual
3AFE68746299
ACS800-207LC IGBT Supply Unit Hardware Manual 3AFE68822092
ACS800 IGBT Supply Control Program Firmware Manual 3AFE68315735
INVERTER UNIT HARDWARE MANUALS
1)
ACS800-107LC Inverter Unit Hardware Manual 3AFE68715491
BRAKE CHOPPER MANUALS
3)
ACS800-607LC Brake Chopper Units Hardware Manual 3AFE68835861
ACS800 Brake Chopper Control Program Firmware Manual 3AFE68835631
INVERTER UNIT FIRMWARE MANUALS,
SUPPLEMENTS AND GUIDES
3)

Standard Application Program Firmware Manual and
Adaptive Program Application Guide
3AFE64527592,
3AFE64527274
System Application Program Firmware Manual and
Adaptive Program Application Guide
3AFE64670646,
3AFE68420075
Application Program Template Firmware Manual 3AFE64616340
Master/Follower Application Guide 3AFE64590430
Pump Control Application Program Firmware Manual 3AFE68478952
Extruder Control Program Supplement 3AFE64648543
Centrifuge Control Program Supplement 3AFE64667246
Traverse Control Program Supplement 3AFE64618334
Crane Control Program Firmware Manual 3BSE11179
etc.
OPTION MANUALS
3)
Manuals for Fieldbus Adapters, I/O Extension Modules etc.
LIQUID COOLING UNIT MANUAL
4)
ACS800-1007LC Liquid-cooling Unit User's Manual 3AFE68621101
1)
Always included in the delivery
2)
Included in the delivery with appropriate supply unit
3)
Included in the delivery with appropriate program or option device
4)
Included in the delivery with the optional liquid cooling unit
ACS800-207LC
IGBT Supply Units
Hardware Manual
3AFE68822092 Rev A
EN
EFFECTIVE: 30.03.2007
! 2007 ABB Oy. All Rights Reserved.
Table of contents
5
Table of contents
Table of contents
About this manual
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Common chapters for several products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation and commissioning flowchart of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Other documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
How the IGBT supply unit operates
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
AC voltage and current waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Hardware description
Overview of a drive with an IGBT supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Composition of the supply unit cubicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Layout view Auxiliary control cubicle (option +Z010 or +Z020) . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Layout view Main contactor cubicle (option +F250) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Layout view Main breaker cubicles (option +F255) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
600 mm wide cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1000 mm wide cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Layout view Supply module and LCL filter cubicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Single-line diagram of a supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Overview of IGBT supply module R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Connections and use of the IO in the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Connections to standard I/O terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Type designation labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Type code of cabinet-installed IGBT supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Basic code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Option codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Table of contents
6
Type code of IGBT supply module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Basic code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Option codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Electrical installation
Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Input cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Checking the compatibility with IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Power connections unit with in-built main breaker or contactor (option +F255 or +F250) . . . . . 32
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Power connections unit without in-built main breaker or contactor (no option +F255 or +F250) 34
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Main breaker/contactor control connections unit without in-built main breaker or contactor
(no option +F255 or +F250) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installation of optional modules and PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
PC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installation of option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Cabling of I/O and fieldbus modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fibre optic links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Connections of the auxiliary voltage transformer (option +G344) . . . . . . . . . . . . . . . . . . . . . . . . . 38
Connection of external power supply for the auxiliary circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Connection diagram, case 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Installation checklist
Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Start-up and operation
Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Fault tracing
LEDs of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Table of contents
7
Maintenance
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Replacing and reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Capacitor replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Replacing the cooling fans in incoming cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Replacing the fan in 400 mm wide incoming cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Replacing the fan in 600 mm or 1000 mm wide incoming cubicle . . . . . . . . . . . . . . . . . . . . . . . 51
Replacing the cooling fans in supply module cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Installing the installation stand for supply module R8i replacement . . . . . . . . . . . . . . . . . . . . . . . . 53
Replacing the supply module R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Installing the winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
The internal cooling circuit
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Internal cooling system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Connection to a cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Connection to an ACS800-1007LC cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Connection to a custom cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
General requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Coolant temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Filling up and bleeding the internal cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Draining the internal cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Adding inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Temperature limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Pressure limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Water quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Freeze protection and corrosion inhibition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Glycol concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Technical data ACS800-207LC
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Auxiliary circuit current consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Losses, coolant flow and quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Internal cooling circuit data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Input busbar and cable lead-through data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Table of contents
8
Units with built-in main breaker (option +F255) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Input power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Output power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Standards and markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
US patents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Technical data ACS800-104LC modules
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Type equivalence table and frame sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Auxiliary circuit current consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
LCL filter types, data and use with supply modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Supply module capacitances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Losses, coolant flow and quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
AC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
DC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Output connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Input power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Tightening torques for power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
US patents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Dimensions and weights
Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Cubicle widths and positions in the cabinet line-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Cubicle widths and positions in the IGBT supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Motor control and I/O board (RMIO) specification
To which board type and revisions this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
RMIO board specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Analogue inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Constant voltage output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Table of contents
9
Auxiliary power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Analogue outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
DDCS fibre optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
24 V DC power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
IGBT supply unit example circuit diagrams
Table of contents
10
About this manual
11
About this manual
What this chapter contains
This chapter describes the intended audience and contents of the manual. It also
contains an installation and commissioning flowchart and the ABB contact
information.
Compatibility
This manual is compatible with ACS800-207LC, the liquid-cooled and cabinet-
installed IGBT supply units.
Intended audience
This manual is intended for people who plan the installation, install, commission, use
and service the supply unit. 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.
Common chapters for several products
Some chapters apply also to ACS800-104LC IGBT supply module or the complete
multidrive. This is indicated in the introduction of the chapter.
Contents
The ACS800-207LC Hardware Manual:
describes the operation basics and hardware of the supply unit
instructs in safe installation, start-up, fault tracing and maintenance of the supply
unit
presents or refers to the essential reference data, such as technical data, system
and circuit diagrams, that help the customer in planning the installation, installing,
commissioning, using and maintaining the supply unit.
About this manual
12
Installation and commissioning flowchart of the drive
Task Additional information
Plan the installation, e.g:
select cables and motors
define/check supply disconnecting means, protections,
emergency stop means, prevention of unexpected start-
up means
See ACS800 Liquid-cooled Multidrive and Multidrive
Modules Planning the Electrical Installation
[3AFE68715423 (English)], chapter Technical data
ACS800-207LC, and the technical data in ACS800-107LC
Inverter Unit Hardware Manual [3AFE68715491 (English)].
verify that the ratings (voltage, current, power) of input
power line, drive and motors match with each other
check the ambient conditions See chapter Technical data ACS800-207LC, page 67.
check that the cooling arrangements both in internal and
external cooling circuits meet the requirements: materials,
coolant quality, coolant flow, coolant temperature and
pressure.
See chapters The internal cooling circuit, page 59 and
Technical data ACS800-207LC, page 67 and
ACS800-1007LC Liquid Cooling Unit User's Manual
[3AFE68621101 (English)].
Unpack the drive and make the delivery check.
Check that all necessary optional modules and equipment
are present and correct.
Only intact units may be started up!
See Option codes, page 27.
If the drive has been non-operational for more than one
year, reform the converter DC link capacitors.
Contact your local ABB representative.
Route the cables. See ACS800 Liquid-cooled Multidrive and Multidrive
Modules Planning the Electrical Installation
Fasten the transportation lengths and mount the cabinet
line-up.
See ACS800 Liquid-cooled Multidrive Mechanical
Installation [3AFE68715466 (English)].
Check the insulation of the input power cable, motor cable
and motor.
See chapter Electrical installation, page 31.
Connect the power cables. Connect the control cables.
Connect the external power supply for the auxiliary circuits
(if needed).
See chapter Electrical installation, pages 31, 34, 36 and 39.
See the circuit diagrams delivered with the drive.
Connect cooling circuits.
About this manual
13
Other documents
User documentation of a multidrive delivery contains technical drawings and a set of
manuals. Technical drawings are tailor-made for each delivery. The composition of
the manual set depends on the composition of the drive. For the list of manuals, see
the inside of the front cover.
Terms and abbreviations
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.
Product and service inquiries
Address any inquiries about the product to your local ABB representative, quoting
the type code and serial number of the unit in question. A listing of ABB sales,
support and service contacts can be found by navigating to www.abb.com/drives and
selecting Drives World wide service contacts on the right pane.
Check the installation. See chapter Installation checklist, page 41.
Commission the drive. See chapter Start-up and operation, page 43.
Term Definition
APBU PPCS Branching and Data logger Unit. Handles the communication between the control
board (RMIO) and parallel supply modules or inverter modules.
DDCS Serial communication protocol used in ABB drives
R8i Inverter module or IGBT supply module frame size
RAIO Analogue I/O extension module (optional)
RAPI 24 V DC back-up accumulator board for auxiliary power of RMIO board
RDCO DDCS Communication Option. A satellite board that can be snapped on the RMIO board
to add the no. of fibre optic channels available.
RDCU Drive Control Unit. The RDCU houses the RMIO board inside a plastic casing which can
be snapped on a standard installation rail.
RDIO Digital I/O extension module (optional)
RMIO Motor Control and I/O Board. In ACS800 multidrive, there is one RMIO board in each
supply unit, inverter unit, brake unit and cooling unit.
Task Additional information
About this manual
14
Product training
For information on ABB product training, navigate to www.abb.com/drives and select
Drives Training courses on the right pane.
Providing feedback on ABB Drives manuals
Your comments on our manuals are welcome. Go to www.abb.com/drives, then
select successively Drives Document Library Manuals feedback form on the right
pane.
15
This chapter describes how the IGBT supply unit operates. The information is valid
for cabinet-installed IGBT supply units (ACS800-207LC), and IGBT supply modules
(ACS800-104LC) if they are equipped with similar auxiliary devices.
Operation principle
The IGBT supply unit consists of an IGBT supply module, an LCL filter, AC and DC
fuses and optional devices such as main breaker, etc. The IGBT supply module
rectifies three-phase AC current to direct current for the intermediate DC link of the
drive. The intermediate DC link is further supplying the inverter that runs the motor.
There might be one inverter only (single drive) or several inverters (multidrive)
connected to the intermediate circuit. The line filter suppresses the AC voltage
distortion and current harmonics.
The IGBT supply module is a four-quadrant switching-mode converter, i.e. the power
flow through the converter is reversible. As default, the 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. Two line currents and the DC link voltage are
measured and used for the control.
The LCL filter is an essential part of the IGBT supply unit. The high AC inductance
smooths the line voltage waveform distorted by the high-frequency switching of the
converter. Capacitive component of the filter effectively filters the high-frequency
(over 1 kHz) harmonics.
LCL filter DC fuses IGBT supply module AC fuses
DC output
AC input
16
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 harmonics 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). See chapter Technical data
ACS800-104LC modules, page 73. The voltage ripple depends on the ratio of supply
line inductance (L
supply line
) to total line inductance (L
supply line
+ L
LCL filter
).
Typical line current (i
U
) and voltage (u
UV
) waveforms are shown below.
Typical current distortion at the input of the supply transformer is shown below. Each
harmonic is presented in relation to a reference current of 200 A.
-1200
-800
-400
0
400
800
1200
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38
u
UV
t [ms]
i
U
I [A], U [V AC]
0.00
0.20
0.40
0.60
0.80
1.00
1.20
2 6 10 14 18 22 26 30 34 38 42 46 50
T
H
D

C
u
r
r
e
n
t

[
%
]

Ordinal no. of
harmonic
17
This chapter describes the hardware of the IGBT supply unit. The information is valid
for cabinet-installed IGBT supply units (ACS800-207LC), and IGBT supply modules
Overview of a drive with an IGBT supply unit
The figure below shows an example of a multidrive line-up. Every line-up typically
includes a supply unit, inverter units and liquid cooling unit. The composition, and
size of the units vary. The line-up may also include additional units and cubicles, e.g
an auxiliary control unit (or cubicle), a control unit, adapter cubicles, etc.
Composition of the supply unit cubicles
The composition of supply unit depending on the selected options is described in
chapter Cubicle widths and positions in the IGBT supply unit. The layout drawings of
the cubicles are shown below.
No. Description
1. Supply unit
1a. Auxiliary control cubicle
1b. Main breaker
(contactor) cubicle
1c. LCL filter cubicle
1d. Supply module cubicle
2. Inverter unit
3. Inverter unit
4. Cooling unit
1b 1d 2 3 4 1c
0 1
1
1a
18
Layout view Auxiliary control cubicle (option +Z010 or +Z020)
Layout view Main contactor cubicle (option +F250)
No. Description
1. Main switch for auxiliary circuits
2. Auxiliary voltage transformer
3. Control relays, breakers, etc.
4. Cooling fan
5. Air to liquid heat exchanger
Door closed Door open
1
2
3
5
4
No. Description
1. Emergency stop, reset (optional)
2. Meters (optional)
3. Operating switch of the supply unit (Off/
On/Start)
4. PE main busbar of the cabinet (behind the
cooling liquid pipe)
5. Busbars for input power cables
6. Main disconnector (option +F254)
7. Earthing switch (option +F259)
8. Charging circuit/switch
9. Main contactor
10. Heat exchanger and fan
1
2
3
10
6
8
7
9
4
5
19
Layout view Main breaker cubicles (option +F255)
600 mm wide cubicle
1000 mm wide cubicle
No. Description
On/Start)
6. Charging circuit switch
7. Main breaker
8. Earthing switch
9. Heat exchanger and fans
3
1
2
6
7
9
8
4
5
No. Description
On/Start)
6. Charging circuit switch
7. Main breaker
8. Earthing switch
9. Heat exchanger and fans
Doors closed Doors open
1
2
3
6
7
8
4
5
9
20
Layout view Supply module and LCL filter cubicles
Figure below is an example showing a unit with two parallel R8i modules.
No. Description
1. Control panel (option +J400)
2. LED panel (option +J401)
3. AC fuses
4. LCL filter components (2 L, 1 C)
5. Swing-out frame for the supply unit control
electronics
6. Supply modules (behind the swing-out
frame)
7. Fans
8. DC fuses
Doors closed Doors open
1 2
3
6
7
8
4
5
21
Single-line diagram of a supply unit
The single-line diagram below shows a two-module IGBT supply unit with a built-in
main breaker and an earthing switch (option +F259).
Overview of IGBT supply module R8i
The figure below shows the IGBT supply module size R8i. The control unit (type
RDCU) containing the RMIO board is external and not shown here.
U<
LCL
2ACS800
RMIO
Control circuitry
board
-104LC
~
=
APBU
board
~
=
5) 6)
1. Input power connection
2. DC supply for inverters
3. Power supply for fans
4. Power supply for control circuitry
5. Temperature supervision
6. IGBT supply module control via
fibre optic link
0
START
1
1
2
3
4
1. Input busbars/knives (U2,V2,W2). Fit into
quick connector on the rear assembly plate of
the cabinet.
2. Output busbars (+, -)
3. Fibre optic connectors. V1, V2: control board
(RMIO) connection. Other fibre optic
connectors are not in use in supply units.
4. Coolant in connection
5. Coolant out connection
6. Handle
7. Air/liquid heat exchanger
8. Terminal block X17 (not in use in supply units)
1
2
3
4
5
7
6
8
22
Printed circuit boards
The figure below shows the interconnections between the boards.
1)
The RDCU can optionally equipped be with an auxiliary power interface board (RAPI). The RAPI
board ensures the POWER FAIL function of the RMIO board can be carried out in case the 24 V
auxiliary power to the RDCU is interrupted, i.e. the fault and alarm loggers have enough time to write
collected data into the flash memory.
Item Explanation
RDCU Drive control unit. Note that in units with several modules in parallel, there is a branching
unit (APBU or NPBU) between the modules and the control unit.
RMIO Control board
APOW Power supply board
NRED Voltage reduction board (in 690 V AC units only)
AINT Main circuit interface board
AGDR Gate driver board (interface to IGBTs)
AINT
Intermediate
DC link
NRED
1
3
X4
X2
2
AGDR
X10 X2
AGDR
X10 X2
AGDR
AINT
X10 X2
X1
X7
APOW
X1
X2 X8
Phase current
measurements
(3)
IGBT control
pulses
V2
RMIO
RDCU
V68 V1
V57
X2
X34
IGBT supply module
2
V5
24 V
1)
n
X2
X3
23
Control interfaces
The following diagram shows the control interfaces and I/O options of the supply
unit.
~
= ~
=
Motor Control
and I/O Board
(RMIO)
Supply unit control circuitry
including door switches, charging
circuit control, main contactor
control, etc.
Input power
To motor
Optional module 1: Fieldbus adapter (e.g.
RMBA, RDNA, RPBA)
Optional module 2: Not in use when the
board controls an IGBT supply module.
Optional module 3: DDCS communication
option (RDCO-0x)
The fibre optic channels provided by the
RDCO module can be used for fieldbus
connection (Nxxx fieldbus adapter modules),
or PC connection (DriveWare
PC tools). See
ACS800 IGBT Supply Control Program
Firmware Manual [3AFE68315735 (English)].
Drive Control Unit
(RDCU)
Control panel or LED
panel
Supply unit Inverter unit
0
St
1
Reset
Em. stop
24
Connections and use of the IO in the supply unit
The table and the figure below describe the connections and use of the IO in the
supply unit. The use of IO is fixed in the supply unit control program and the wiring to
RMIO terminals are made accordingly at the factory. The settings of the supply
control program and the connections of the supply unit IO must not be changed by
the user.
IO Name Use in the control program Connected device / Purpose
RDCU standard IO channel
AI1 Not in use Not in use as default. Not in use as default.
A12 Not in use Not in use as default. Not in use as default.
AI3 Not in use Not in use as default. Not in use as default.
DI1 ALARM / FAULT Overtemperature supervision: 1->0: Alarm.
0: Fault (after preset time delay).
LCL filter temperature sensors (in series)
DI2 ON / OFF Supply module on/off control. 0->1: On.
0: Off.
Operating switch, control circuitry
DI3 ACK MAIN
CONTACTOR
Main breaker/contactor supervision. 1:
closed (enables supply unit start)
Contact in main breaker/contactor control
circuit
DI4 EARTH FAULT Earth fault supervision. Can be activated or
inactivated by parameter. 1: No fault. Not in
use as default.
Insulation monitoring device (optional IRDH
unit by Bender, +Q951 or +Q952).
DI5 ALARM / FAULT Supervision of cooling unit. Can be activated
or inactivated by parameter. 1->0: Alarm.
0: Fault (after preset time delay). Not in use
as default.
Cooling unit monitoring circuit. Not in use but
hard-wired to +24 VDC of RDCU when no
optional cooling unit is in use.
DI6 RESET Supply module reset. 1: Reset. Not connected as default. Fault reset can be
given from control panel.
DIIL Not in use Not in use as default. Not in use as default.
RO1 CHARGING On/off control of charging contactor. 1: On. Charging circuit control relay
RO2 LCU ON / OFF Liquid cooling unit on/off control. 1: On. Cooling unit control relay. Not connected
when no optional cooling unit is in use
(+C138 or +C139).
RO3 MAIN
CONTACTOR
CONTROL
Main breaker/contactor control. 1: On. Breaker control circuit
25
Connections to standard I/O terminals
X20
1 VREF- Reference voltage -10 V DC, 1 kohm < R
L
< 10
kohm
2 AGND
X21
1 VREF+ Reference voltage 10 V DC, 1 kohm < R
L
< 10
kohm
2 AGND
3 AI1+ Not in use. 1) 0(2)10 V, R
in
> 200 kohm
4 AI1-
5 AI2+ Not in use. 1) 0(4)20 mA, R
in
= 100 ohm
6 AI2-
7 AI3+ Not in use. 1) 0(4)20 mA, R
in
= 100 ohm
8 AI3-
9 AO1+ Not in use. 1) 0(4)20 mA, R
L
< 700 ohm
10 AO1-
11 AO2+ Not in use. 1) 0(4)20 mA, R
L
< 700 ohm
12 AO2-
X22
1 DI1 ALARM / FAULT
2 DI2 ON / OFF
3 DI3 ACK MAIN CONTACTOR
4 DI4 EARTH FAULT 1)
5 DI5 ALARM / FAULT 1)
6 DI6 RESET 1)
7 +24V +24 V DC max. 100 mA
8 +24V
9 DGND1 Digital ground
10 DGND2 Digital ground
11 DIIL Not in use 1)
X23
1 +24V Auxiliary voltage output, non-isolated, 24 V DC
250 mA
2 GND
X25
1 RO1 Charging contactor control: Open (0) /
close (1)
2 RO1
3 RO1
X26
1 RO2 LCU control: Off (0) / on (1)
2 RO2
3 RO2
X27
1 RO3 Main breaker/contactor control: open (0)
/ close (1)
2 RO3
3 RO3
1) Not in use as default.
For details, see the delivery specific
circuit diagrams of the cabinet-installed
unit. The diagrams show:
- supply unit on/off control
- main breaker supervision and on/off
control
- charging contactor on/off control
- optional auxiliary circuit wiring.
WARNING! Starting sequence, i.e.
charging, acknowledgements, main
breaker/contactor control and the
supply unit start, follows a certain order.
Never change the order by by-passing
signals (using jumpers), etc. That will
cause a malfunction that may damage
the unit.
Terminal block size:
cables 0.3 to 3.3 mm
2
(22 to 12 AWG)
Tightening torque:
0.2 to 0.4 Nm (0.2 to 0.3 lb.ft)
START
1
0
3
4
1
2
Control circuitry
Main breaker/contactor
Charging contactor
Operating switch
26
Type designation labels
The type designation label includes the ratings, valid markings, a type code and
a serial number. The supply module label is attached to the front panel of the module
and the label of the supply unit is attached to the inner side of the unit door. Example
labels are shown below.
No. Description
1. Serial number. The first digit of the serial number refers to the manufacturing plant. The next
four digits refer to the units manufacturing year and week, respectively. The remaining digits
complete the serial number so that there are no two units or modules with the same number.
2. Type code. See sections Type code of cabinet-installed IGBT supply unit on page 27 and
Type code of IGBT supply module on page 30.
3. Valid markings
4. Ratings of supply unit
5. Ratings of converter module when in supply module use
6. Ratings of converter module when in inverter use
Type designation label of ACS800-207LC supply unit
1
2
4 3
Type designation label of ACS800-104LC supply and inverter module
1
2
3
6
5
27
Type code of cabinet-installed IGBT supply unit
Type code describes the composition of the unit in short. The type code is visible on
the type designation plate (sticker) which is attached to the cabinet. The complete
code is divided in sub-codes:
The first 19 digits form the basic code. It describes the basic construction of the
unit. The fields in the basic code are separated with hyphens.
The option codes follow the basic code. Each option code starts with an
identifying letter (common for the whole product series), followed by descriptive
digits. The option codes are separated by plus signs.
Basic code
Option codes
This is a common list for the liquid-cooled supply units of ACS800 liquid-cooled
multidrive. Not all options are available for the IGBT Supply Unit (ACS800-207LC).
Option codes starting with the symbol zero (0) are selections that are not shown on
the nameplate (internal codes for the factory use). Default selections are marked by
* in the table below.
Digit no. Name Alternatives Description
16 Product series ACS800 Industrial drives
810 Construction 207 IGBT Supply Unit
11, 12 Cooling LC Liquid-cooling
1417 Size 2405450 Size of the unit
19 Voltage rating 3 380415 V
5 380500 V
7 380690 V
Class Code Description
Supply frequency A012 Supply frequency 50 Hz *
A013 Supply frequency 60 Hz
Degree of protection B054 IP42, UL type 1, NEMA 1 *
B055 IP54, UL type 12, NEMA12
Cabinet construction 0C121 Industrial construction *
C121 Marine construction
Standards 0C129 IEC standards *
C134 CSA-approved components
C129 UL-approved components
Cooling unit type 0C138 No cooling unit *
C138 Line-up connected cooling unit
C139 Stand-alone cooling unit
Pipe connection side C143 Pipe connection on right *
C144 Pipe connection on left
Connection flange 0C145 DIN flanges *
C145 ANSI flanges
EMC/RFI-filters 0E202 No E202 *
E202 EMC/RFI-filter, 1st environment, restricted (A-limits,
earthed network)
28
EMC 0E210 No E210 *
E210 2nd environment
Line options 0F250 No E250 *
F250 Line contactor
F254 Switch fuse
Breaker option 0F255 No F255 *
F255 Circuit breaker
Earthing switch 0F259 No F259 *
F259 Earthing switch
Cabinet options G300 Cabinet heater
Control voltage for relays and fans G320 230 V AC *
G304 115 V AC
Terminals for external control voltage 0G307 No G307 *
G307 Terminals for external control voltage
DC bus material G315 Tin plated copper
Wiring materials 0G330 Standard wire material *
G330 Halogen free wiring
Supply conductor type G316 Cable supply conductors *
G317 Busbar supply conductors
Arc monitoring 0G336 No G336 (no arc monitoring) *
G336 Arc monitoring
G337 Arc monitoring with current sensing unit
Electrical disconnect button 0G332 No G332 *
G332 Electrical disconnect push button on the door (black)
Q959 Supply transformer braker disconnect push button (red)
on the door
Meters 0G334 No G334 (no meters on door) *
G334 V-meter with selector switch
G335 A-meter in one phase
3G335 A-meter in three phases
G333 kW-meter
Auxiliary voltage transformer 0G344 No G344 *
G344 Auxiliary transformer
Power cabling entry H350 Bottom entry *
H351 Top entry
Control cabling H367 Control cable bottom *
H368 Control cable top
Cable gland

0H365 No H365 (no cable glands) *
H365 Cable gland plates (brass 6mm, undrilled)
H364 Cable gland plates (aluminium 3mm, undrilled)
H358 Cable gland plates (steel 3mm, undrilled)
Auxiliary control unit (ACU) 0Z010 No Z010 (no ACU) *
Z010 ACU width 400
Z020 ACU width 600
Drive window option Z040 Drive window selected (plastic + silica)
DriveBus branching unit 0Z050 No Z050 *
Z050 NDBU-44
Emergency stop acknowledgment Z150 Via RMIO
Z160 Via AC800
Emergency stop location Z170 Standard
Z180 Master
Z190 Follower
CDP-panels 0J400 No J400
J400 Control panel CDP 312R *
LMD-panels 0J401 No J401 *
J401 Drive monitoring display
Panels 0K450 No K450 (no panels) *
J410 Drive control panel connection kit
K450 Panel Bus selected
29
ON/OFF control type 0J411 No J411 *
J411 Remote supply control
Fieldbus type 1 0K451 No K451 (no fieldbus type 1) *
K451 RDNA-01 (DeviceNet)
K452 RLON-01 (LONWorks)
K454 RPBA-01 (Profibus)
K458 RMBA-01 (Modbus)
K462 RCNA-01 (Control Net)
K464 RETA-01 (Ethernet)
Fieldbus type 2 0ZK458 No ZK458 (no fieldbus type 2) *
ZK458 RMBA-01 (Modbus adapter) with another fieldbus
Fieldbus type 3 0K453 No K453 (no fieldbus type 3) *
K453 NIBA-01 (Interbus-S)
K455 NMBP-01 (Modbus Plus)
K456 NAFA-01 (AF100)
K457 RCAN-01 (CANOpen)
I/O options L503 DDCS communication 3
L509 DDCS communication 2 *
L508 DDCS communication 1
Special options G343 Corrosion coupon in ACU
P902 Customised (described in technical appendix)
P904 Extended warranty
P913 Special colour (described in technical appendix)
Emergency stop 0Q951 No Q951 (no emergency stop) *
G331 Emergency stop push button on the door (red)
Q951 Emergency stop, stop category 0
Q952 Emergency stop, stop category 1
Earth fault monitoring 0Q953 No Q953 (no earth fault monitoring device) *
Q953 Earth fault monitoring, earthed mains TN
Q954 Earth fault monitoring, unearthed mains IT
Safety category 0Q962 No Q962 (no safety category selected) *
Q962 Safety category 1
Q961 Safety category 3
Documentation languages R700 English *
R701 German
R702 Italian
R703 Dutch
R704 Danish
R705 Swedish
R706 Finnish
R707 French
R708 Spanish
R709 Portuguese (spoken in Portugal)
R710 Portuguese (spoken in Brazil)
R711 Russian
R712 Chinese
Power rating of control voltage
transformer
0Z260 No Z260 (no control voltage transformer) *
Z260 2500 VA
Z280 4000 VA
Z290 6300 VA
Z300 9000 VA
Z310 12000 VA
External control voltage supply / UPS
size
Z225 Max. current 16 A
Motor options Z1220 Supply for motor fan
Z1230 Supply for motor heater
30
Type code of IGBT supply module
Each module has a type designation label attached, containing e.g. the type code of
the module. The type code contains information on the specifications and
configuration of the module.
The first 19 digits form the basic code. It describes the basic construction of the
module. The fields in the basic code are separated by hyphens.
The option codes follow the basic code. Each option code starts with an
identifying letter (common for the whole product series), followed by descriptive
digits. The option codes are separated by plus signs.
Basic code
Option codes
Digit no. Name Alternatives Description
16 Product series ACS800 Industrial drives
810 Construction 104 IGBT supply module or inverter module
11, 12 Cooling LC Liquid-cooling
1417 Size 3106620 Size of the module
19 Voltage rating 3 380415 V
5 380500 V
7 380690 V
Ident.
letter
Name/Description Alternatives Description
A Supply frequency A013 60 Hz
E Filters E205 Internal (du/dt) filters. This feature is standard.
Frames R8i and nR8i only.
G Supply voltage for
fan
G304 115 V AC
31
This chapter instructs how to check the insulation of the assembly and how to install
the input power cables and control cables. The information is valid for cabinet-
installed IGBT supply units (ACS800-207LC), and IGBT supply modules
For information on the mechanical installation of the cabinet line up, see ACS800
Liquid-cooled Multidrive Mechanical Installation [3AFE68715466 (English)].
For information on the installation planning, i.e. cable selection, protections, etc. see
ACS800 Liquid-cooled Multidrive and Multidrive Modules Planning the Electrical
Before installation
Checking the insulation of the assembly
WARNING! Before start, read and follow the instructions given in manual ACS800
Liquid-cooled Multidrive and Multidrive Modules Safety Instructions
[AFE68715318 (English)]. Ignoring the instructions can cause physical injury or
death, or damage to the equipment.
Drive
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.
Input cable
Check the insulation of the input cable according to local regulations before
connecting it to the drive.
Motor and motor cable
Check the insulation of the motor and motor cable as follows:
Check that all motor cables are disconnected from the drive output terminals U2,
V2 and W2.
Measure the insulation resistance of the motor cable and 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. PE
ohm
M
32
Checking the compatibility with 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
an ungrounded power line. For detailed instructions on how to do this, please
contact your local ABB representative.
Power connections unit with in-built main breaker or contactor
(option +F255 or +F250)
Connection diagram
U<
Q1
PE
L1
L2
L3
2)
1)
3)
Main breaker cubicle
~
=
Notes:
1)
Input power connection: L1, L2, L3 and PE. To be wired by the user.
For selection of input power cables, see manual Planning the Electrical installation
For the power cable terminal sizes and cabinet lead-through sizes, see section Input busbar and
cable lead-through data on page 70.
For the power cable terminal tightening torques, see section Connection procedure on page 33.
2)
Main breaker (option code +F255)
Type of the main switching and disconnecting devices vary. Contactor and switch fuse are used
instead in smaller units (options +F250 and +F254). The unit may also include a grounding switch
(option +F259).
3)
Charging circuit
Supply module and LCL
filter cubicles
33
Connection procedure
1. Release the handle and open the door of the main breaker or contactor cubicle.
2. Remove the shroud that protects the input busbars and cable lead-throughs.
3. Lead the cables into the inside of the cabinet and connect as follows:
Twist the cable shields to bundles and connect to cabinet PE (ground) busbar.
Connect the separate PE conductors/cables (if exist) to cabinet PE (ground)
busbar. Tightening torque = 70 Nm [55 lb.ft].
Connect the phase conductors to the input power terminals. Tightening
torque = 70 Nm [55 lb.ft].
4. Replace the protecting shroud and close the door.
Detail of cable lead-through
To suppress interference, use shielded
three-phase cables and ground the
shields 360 at the lead-through.
2
3
Input busbars
34
Power connections unit without in-built main breaker or contactor
(no option +F255 or +F250)
Connection diagram
U<
PE
L1
L2
L3
Notes:
1)
Input power connection: L1, L2, L3 and PE. To be wired by the user.
For selection of input power cables, see manual ACS800 Liquid-cooled Multidrive and Multidrive
Modules Planning the Electrical installation [3AFE68818559 (English)].
For the power cable terminal sizes and cabinet lead-through sizes, see section Input busbar and
cable lead-through data on page 70.
For the power cable terminal tightening torques, see section Connection procedure on page 35.
2)
Main breaker. To be acquired and installed by the user.
The actual main disconnecting and switching solution may differ from above. Note, however, that
the disconnecting device is compulsory (refer to local safety regulations).
Wire the main breaker also to the breaker control and supervision circuits in the supply unit
(connections are not shown above). See the circuit diagrams delivered with the unit.
3)
Charging circuit connection. To be wired by the user.
If there is a main breaker (or contactor) in between the supply transformer and the supply unit, wire
as shown above.
If there is no main breaker, use another power source which has the same voltage rating and
phasing as the supply unit and which is capable of delivering the charging current.
2) 1)
3)
Q2.1
~
= 35
46
Incoming
cubicle
Supply module and LCL
filter cubicles
35
Connection procedure
1. Release the handle and open the door of the incoming cubicle.
2. Remove the shroud that protects the input busbars and cable lead-throughs.
3. Lead the input power cables into the inside of the cabinet and connect as follows:
Twist the cable shields to bundles and connect to cabinet PE (ground) busbar.
Connect the separate PE conductors/cables (if exist) to cabinet PE (ground)
busbar. Tightening torque = 70 Nm [55 lb.ft].
Connect the phase conductors to the input power terminals. Tightening
torque = 70 Nm [55 lb.ft].
4. Lead the charging circuit supply cables into the inside of the cabinet and connect
to charging circuit main switch Q2.1.
5. Replace the protecting shroud and close the door.
Detail of cable lead-through
To suppress interference, use shielded
three-phase cables and ground the
shields 360 at the lead-through.
2
3
Input busbars
Charging circuit main
switch (Q2.1)
36
Control connections
General
As standard, the cabinet-installed IGBT supply unit is controlled using the local
control devices mounted on the cabinet door: The off/on/start switch, the reset
button and the emergency stop button. No additional control connections are
needed. However, it is also possible to:
halt the 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.
control the unit with a control panel (option +J411)
control the unit through a serial communication interface (option +J411).
See the circuit diagrams delivered with the unit for the default control connections
and the connection terminals. See also start/stop instructions in chapter Start-up and
operation.
Note: Route the control cables away from motor cables.
Main breaker/contactor control connections unit without in-built main breaker or
contactor (no option +F255 or +F250)
Wire the breaker control circuit and supervision circuits to the breaker. See the circuit
diagrams delivered with the unit.
Installation of optional modules and PC
PC connection
WARNING! Read and follow the instructions given in manual ACS800 Liquid-cooled
Multidrive and Multidrive Modules Safety Instructions [3AFE68715318 (English)].
Ignoring the instructions can cause physical injury or death, or damage to the
equipment.
Connect PC to CH3 of RDCO board via a fibre optic link. RDCO is attached to an
option slot of the RDCU unit. See also Fibre optic links below.
Installation of option modules
WARNING! Read and follow the instructions given in manual ACS800 Liquid-cooled
equipment.
Insert optional modules (such as fieldbus adapters, I/O extension modules and pulse
encoder interfaces) into the optional module slots of the RDCU unit and secure with
37
two screws. The slots on the RDCU unit are described in Control interfaces on page
23. See also the appropriate optional module manual for information on the cable
connections.
Cabling of I/O and fieldbus modules
Fibre optic links
DDCS fibre optic links are provided by RDCO module for PC tools, master/follower
link, NDIO, NTAC, NAIO, AIMA I/O module adapter and fieldbus adapter modules of
type Nxxx. See the RDCO Users Manual [3AFE64492209 (English)] for the details.
Observe colour coding when installing fibre optic cables. Blue connectors go to blue
terminals and grey connectors to grey terminals.
When installing multiple devices on the same channel, connect them in a ring.
Shield
Module
234 1
Keep unshielded portion as
short as possible
To nearest PE terminal
38
Connections of the auxiliary voltage transformer (option +G344)
The transformer connections have been done at the factory as default. Normally
there is no need to change or adjust the ready-made connections.
500 V AC
460 V AC
440 V AC
415 V AC
400 V AC
380 V AC
0 1
21
22
23
24
25
26
0 (Ground)
115 V AC
230 V AC
2
3
4
5
6
7
690 V AC
660 V AC
600 V AC
575 V AC
525 V AC
0 1
21
22
23
24
25
26
0 (Ground)
115 V AC
230 V AC
2
3
4
5
6
Transformer for 380500 V AC input voltage
Transformer for 525690 V AC input voltage
39
Connection of external power supply for the auxiliary circuits
There are four alternative means to arrange the power supply for the auxiliary circuit
(= fans and control circuitry). See manual ACS800 Liquid-cooled Multidrive and
Multidrive Modules Planning the Electrical Installation [3AFE68715423 (English)] for
details. This section illustrates the user connections for those three cases (case 2, 3
and 4) in which the drive fans and/or control circuitry must have an external supply.
Note that case 1 drive with an auxiliary voltage transformer and with no terminals
for external control voltage (UPS) does not require any external wiring and
therefore it is not shown here.
Connection diagram, case 2
>
L N
Note:
Connect the external auxiliary power supply for control circuitry to terminal block X11 in the auxiliary
control unit cubicle (fans are supplied from internal auxiliary voltage transformer - no user
connections required). Dimension the supply on basis of the auxiliary devices used in the drive. See
ACS800 Liquid-cooled Multidrive and Multidrive Modules Planning the Electrical Installation.
L1
L2
L3
PE
>
L N
N L
Power supply for control
circuitry
Power supply for fans
Option selections
+G344 Auxiliary voltage transformer = Yes
+G307 Terminals for external control
voltage (UPS)
= Yes
T10
Q10
F11 F19
X11
1 2
PE
PE5
40
>
circuitry and fans
PE
>
L N
Note:
Connect the external auxiliary power supply (control circuitry and fans) to X11 in the supply module
cubicle. Dimension the supply on basis of the auxiliary devices used in the drive. See ACS800
Liquid-cooled Multidrive and Multidrive Modules Planning the Electrical Installation.
Option selections
+G344 Auxiliary voltage transformer = No
voltage (UPS)
= No
X11
F19 F11
1 2 PE5 3 4 PE6
PE
>
circuitry
Power supply for fans
L N PE
>
L N
Note:
Connect the external auxiliary power supplies to terminal block X11 in the supply module cubicle.
Dimension the supply on basis of the auxiliary devices used in the drive. See ACS800 Liquid-cooled
Multidrive and Multidrive Modules Planning the Electrical Installation.
Option selections
+G344 Auxiliary voltage transformer = No
voltage (UPS)
= Yes
F19
F11
1 2 PE5
X11
3 4 PE6
41
This chapter contains a list for checking the mechanical and electrical installation of
the drive.
Check the mechanical and electrical installation of the drive before start-up. Go
through the checklist below together with another person.
WARNING! Read and follow the instructions given in ACS800 Liquid-cooled
equipment.
Check
MECHANICAL INSTALLATION
The ambient operating conditions are within the allowed limits. See chapter Technical data ACS800-207LC,
page 71.
The unit has been fixed properly to floor, and if necessary (e.g. marine application) also at the top. See
1)
.
ELECTRICAL INSTALLATION
The motor and the driven equipment are ready for start.
The drive is grounded properly.
The insulation of the input cable, motor cable and motor have been measured. See page 31.
The supply (input power) voltage matches the nominal input voltage of the drive. See page 82.
The supply (input power) connection to the input terminals is OK. See page 32 and
1)
.
Appropriate supply (input power) disconnector is installed.
The motor connections at the output terminals are OK. See
2)
and
3)
.
The motor cable is routed away from other cables. See
4)
.
No power factor compensation capacitors are connected to the motor cable.
The external control connections to the drive are OK. See
2)
.
There are no tools, foreign objects or dust from drilling inside the drive.
Supply (input power) voltage cannot be connected to the output of the drive (with a bypass connection).
For drives with Category 1 Emergency stop function (option +Q952): The time relay has been set to a suitable
value (e.g. somewhat longer than the stop ramp of the inverter units). See
2)
.
42
1)
ACS800 Liquid-cooled Multidrive Mechanical Installation [3AFE68715466 (English)]
2)
Circuit diagrams delivered with the drive.
3)
ACS800-107LC Inverter Unit Hardware Manual [3AFE68715491 (English)]
4)
ACS800 Liquid-cooled Multidrive and Multidrive Modules Planning the Electrical Installation
[3AFE68715423 (English)]
COOLING CIRCUIT See chapter The internal cooling circuit.
The cooling circuit joints at the shipping split joining cubicles are tight.
Bleed and drain valves in all cubicles are closed.
The internal cooling circuit is filled up and bleeded.
Check
43
This chapter instructs how to perform the first start-up and how to operate the supply
unit. The information is valid for cabinet-installed IGBT supply units
(ACS800-207LC), and IGBT supply modules (ACS800-104LC) if they are equipped
with similar auxiliary devices.
WARNING! Only qualified electricians are allowed to commission the drive. Read
and follow the safety instructions delivered with the drive. Neglecting the safety
instructions can cause injury or death.
Start-up
Action Additional information
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.
Ensure that the mechanical and electrical installation of the drive has
been checked according to chapter Installation checklist.
Basic checks with no voltage connected
If the unit is equipped with an air circuit breaker, set the current trip limits
of the breaker.
General rule
Ensure that 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
supply unit.
Peak current limit
As a rule of thumb, this should be set to a value 3-4 times the rated AC
current of the supply unit.
Option +F255. See the delivery specific
circuit diagrams and the breaker
manual.
The trip limits have been preset to
generic values by the breaker
manufacturer. The generic limits do not
correspond the protection requirements
of the application.
Check the settings of the relays and breakers/switches of the auxiliary
circuits.
Optional devices. See delivery specific
circuit diagrams.
Disconnect any unfinished or unchecked 230/115 VAC cables that lead
from the terminal blocks to the outside of the equipment.
Drives with parallel-connected IGBT supply modules and/or inverter
modules: locate the PPCS branching unit (APBU-xx) at the supply
module cubicle (or inverter module cubicle) swing-out frame. Enable
memory backup battery by setting actuator 6 of switch S3 to ON.
By default, memory backup is switched
off to save the battery.
44
Fill up and bleed the internal cooling circuit. Ensure that the coolant can
flow freely in all cubicles. Start the cooling unit up.
See chapter The internal cooling circuit.
For drives with the cooling unit (options
+C140 or +C141), see ACS800-1007LC
Liquid Cooling Unit Users Manual
Install all shrouds and close the doors.
Connecting voltage to input power 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 connect 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.
Units that have earthing/grounding switch (option +F259): Open the
grounding switch.
The switch and the main disconnecting
device are either mechanically or
electrically interlocked so that the
grounding switch can only be closed
when the main disconnecting switch is
open, and vice versa.
Close the main breaker on the primary side of the supply transformer.
Close the main disconnecting device of the drive:
- Units with a built-in main breaker (option +F255): Unlock the withdrawn
breaker and rack it in.
See the breaker manual.
- Units with a built-in main contactor and switch-fuse (option +F250 and
+F254): Close the switch-fuse.
Close the charging circuit switch-fuse. See delivery specific circuit diagrams.
Close the auxiliary circuit switch. See delivery specific circuit diagrams.
Connecting inverters to DC bus
Close the inverter DC switches (option +F266). See ACS800-107LC Inverter Unit
Hardware Manual
[3AFE68808481 English)].
Starting the supply unit and charging the DC bus
Start the supply unit by turning the operating switch on the cabinet door
from 0 into START position for 2 seconds, leave to ON (I) position.
(Note: The drive may also require controls from and overriding controller
or other control device. See the circuit diagrams and other delivery
specific documentation.)
Supply unit first closes the charging
contactor and charges the DC bus after
which it closes the main breaker, opens
the charging contactor and starts
operation.
Checks with the supply unit running
Units with earth fault monitoring device (options +Q953 or +Q954):
Check the settings of the earth fault monitoring device.
Manuals by Bender (manufacturer): IRDH265 manual
(code: TGH1249en), IRDH275/IRDH275B manual (code: THG1361en.)
Optional device. See delivery specific
circuit diagrams and the manual
delivered with the monitoring device.
45
Supply unit control program set-up
The parameter values need not to be set in normal use.
Note: By default, no constant DC voltage reference is set for the IGBT
supply unit but the voltage in the intermediate circuit of the drive is
relative to actual input voltage of the supply unit. As a consequence, a
voltage dip in the AC power line will also decrease the DC voltage of the
drive. In applications where this cannot be allowed, define a constant DC
voltage reference for the supply unit by setting parameter 23.01 DC
VOLT REF to value:
sqrt(2) U
1N
= 1.41 nominal rms voltage of the power line
Note: The control program performs an AC line identification routine
every time the control board is powered up. The routine takes 3 to 7
seconds, only after which the supply unit can be started. It is possible to
deactivate this routine after the first power up if instant start is needed.
See parameters 99.07 and 99.08 in the Firmware Manual.
ACS800 IGBT Supply Control Program
Firmware Manual
Inverter unit application program set-up
Follow the instructions in the Firmware Manual for inverter application
program to start up the inverters.
The firmware manual is included in the
delivery.
On-load checks
Inverter units with the Prevention of Unexpected Start function:
Check that the circuit is connected and works:
- Start and stop the inverter and wait until the motor has stopped.
- Open the Prevention of Unexpected Start switch (mounted on a control
desk).
- Give a start command. The inverter and motor may not start.
- Reset the inverter.
Option +Q950. See delivery specific
circuit diagrams.
Drive with emergency stop function: Check the correct operation of the
emergency stop circuits from each operating location.
Options +Q951 and +Q952. See delivery
specific circuit diagrams.
TN (grounded) power system with earth fault protection based on internal
current measurement: Check the earth fault level (parameter 30.02).
Programmable feature. See ACS800
IGBT Supply Control Program Firmware
Manual [3AFE68315735 (English)].
Make the on-load checks and adjustments of the cooling unit. For drives with the optional cooling unit
(option code +C140 or +C141), see
ACS800-1007LC Liquid Cooling Unit
Users Manual
46
Operating instructions
This generic product manual does not contain the detailed operating instructions as
there is no standardised control means for all engineered drives but they vary greatly
from delivery to delivery. E.g. it is possible to control the supply unit:
by the operating switch on cabinet door solely
from an overriding controller via a fieldbus
by the control panel on cabinet door
by a switch or switches on an operators console
by all or some combination of the above.
For the basic control principles and the related parameters of the supply unit control
program see ACS800 IGBT Supply Control Program Firmware Manual
Fault tracing
47
Fault tracing
This chapter instructs how to interpret the fault indications of the IGBT Supply Unit.
The information is valid for cabinet-installed supply unit types ACS800-207LC, and
for modules ACS800-104LC when equipped with similar auxiliary devices.
LEDs of the drive
Location LED Indication
RMIO board (RDCU drive control
unit)
Red Drive in fault state.
Green The power supply on the board is OK.
Control panel mounting platform
(with the control panel removed)
Red Drive in fault state.
Green The main + 24 V power supply for the control panel and the
RMIO board is OK.
AINT board (visible through the
transparent cover on the front of the
supply/inverter modules)
V204 (green) +5 V voltage of the board is OK.
V309 (red) Prevention of unexpected start is ON.
V310 (green) IGBT control signal transmission to the gate driver control
boards is enabled.
APBU board (only in units with
parallel supply/inverter modules)
RXD led Data is being received from RDCU drive control unit.
TXD led Data is being sent to RDCU drive control unit.
BAT led Memory backup battery voltage is OK.
PWR led 5 V power to on-board logic is OK.
Fault tracing
48
Maintenance
49
Maintenance
This chapter contains a table of maintenance intervals, maintenance instructions.
and the descriptions of LEDs. The information is valid for cabinet-installed IGBT
supply units (ACS800-207), and IGBT supply modules (ACS800-104) if they are
equipped with similar auxiliary devices.
Maintenance intervals
If installed in an appropriate environment, the drive requires very little maintenance.
This table lists the routine maintenance intervals recommended by ABB.
Note: If the drive is equipped with the cooling unit (option +C140 or +C141), see
also the maintenance intervals given in ACS800-1007LC Users Manual
Replacing and reforming the capacitors
The IGBT supply modules employ several electrolytic capacitors. Their life span 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.
Interval Maintenance action Instructions
Every year of storage Capacitor reforming See document ACS800 Capacitor
Reforming Guide
[3BFE 64059629 (English)].
Every 2 years Adding corrosion inhibitor
to the internal cooling
circuit
Add inhibitor. Amount and type: see
chapter The internal cooling circuit, page
59.
Every 6 years Change of fans See sections Replacing the cooling fans in
incoming cubicle on page 50 and
Replacing the cooling fans in supply
module cubicle on page 52.
Every 6 years (units
with parallel-connected
supply modules only)
PPCS branching unit
(APBU-xx) Memory
backup battery renewal
Locate the APBU unit. Switch off the
power to the unit. Remove cover. Replace
battery with a new CR 2032 battery.
Every 12 years Capacitor change Contact an ABB service representative.
Maintenance
50
Reforming
Reform (re-age) spare part capacitors once a year according to Capacitor Reforming
Guide [3AFE64059629 (English)], available from your local ABB representative.
Capacitor replacement
Contact an ABB service representative.
Replacing the cooling fans in incoming cubicle
Replacing the fan in 400 mm wide incoming cubicle
There is 400 mm wide incoming cubicle in units with option +F250 (line contactor).
WARNING! Read and follow the instructions in manual ACS800 Liquid-cooled
equipment.
1. Ensure that the drive is disconnected from the power line and all other
precautions described in ACS800 Liquid-cooled Multidrive and Multidrive
Modules Safety Instructions [3AFE68715318 (English)] have been taken into
consideration.
2. Open the door and remove the shroud to gain access to the fan.
3. Remove the four mounting screws of the fan.
4. Unfasten the power supply cable of the fan and pull the fan out of the cubicle.
5. Remove the four screws that fasten the fan and the fan grille.
6. Install a new fan in reverse order.
3
5
2
Maintenance
51
Replacing the fan in 600 mm or 1000 mm wide incoming cubicle
There is either a 600 mm or a 1000 mm wide incoming cubicle in units with
option +F255 (main breaker contactor).
WARNING! Read and follow the instructions in the manual ACS800 Liquid-cooled
equipment.
consideration.
2. Open the door and remove the shroud to gain access to the fan.
3. Remove the four mounting screws (and the four nuts in 1000 mm cubicle) of the
fan.
4. Unfasten the power supply cable of the fan and pull the fan out of the cubicle.
5. Remove the four screws (and the four nuts in 1000 mm cubicle) that fasten the
fan and the fan grille.
600 mm wide cubicle
1000 mm wide cubicle
3
5
3 5
2
2
Maintenance
52
Replacing the cooling fans in supply module cubicle
equipment.
consideration.
2. Open the door and remove the lower shroud of the cubicle.
3. Unplug the fan power supply.
4. Lift the back part of the fan up a bit and remove the two screws that fasten the
collar to the cubicle. Pull the collar out of the cubicle.
5. Remove the four screws that fasten the fan to the collar.
4
5
Maintenance
53
Installing the installation stand for supply module R8i replacement
1. Fasten the module installation stand to the frame of the cubicle (2 5 screws).
Align the stand and the rails in the cubicle on which the module lies. Adjust the
height of the feet. Note: Remove the cabinet hinge first if necessary.
WARNING! The feet must lean on a solid floor. The cubicle may topple over when
the heavy module is pulled out if the stand is not supported properly.
Do not overtighten (max.
torque 5.5 Nm [4 lbf ft]. En-
sure that the guide studs are
in frame holes before tight-
ening screws.
Fixing of triangle support
Brace
Fixing of braces
Slide plate and support feet
Hooks at this end of plate have
to enter holes in frame cabinet.
With these threads it is possible to fix
the unit to the slide plate.
Do not use more than one
slide plate at a time.
These hooks must enter
holes in the brace.
Maintenance
54
Replacing the supply module R8i
equipment.
consideration.
2. Remove the shrouds: metal grating at the upper and lower part of the cubicle
(four screws each).
3. Close the inlet (a) and outlet (b) valves of the cubicle, and drain the cooling
circuit (see Draining the internal cooling circuit on page 62. Note: Drain (d) and
bleed (c) valves have locking handles. Release the mechanism before turning.
4. Fasten the right-hand side support of the winch to the support frame of the
cubicle (four bolts). Fasten the left-hand side support of the winch to the support
frame of the cubicle (four bolts). Note: Position the guide pins of the supports in
the holes of the cabinet frame before tightening the bolts. For detailed
instructions see Installing the winch on page 58.
5. Install the winch: Lead the crossbeam through the left and right winch support
and the winch body. Lock the crossbeam with two locking pins (a).
6. Open the swing out frame: two screws on the left-hand side, two on the right.
7. Open the locking of the auxiliary hinge of the swing out frame to allow the frame
to open fully: one screw on top (a), one on bottom (b).
8. Decouple the cooling circuit inlet pipe from the module: Unscrew the locking nut
until fully open and pull the pipe out.
9. Decouple the cooling circuit outlet pipe from the module: Unscrew the locking
nut until fully open and pull the pipe out.
Maintenance
55
b
a
c
d
2
Removing the shrouds
3
Draining the cooling unit
4
Fastening the supports of the winch
5
Installing the winch
6
Opening the swing-
out frame
7
Opening the locking
8
Decoupling the inlet (8) and outlet (9)
9
9
8
a
b
a
a
Maintenance
56
10. Unplug the fibre optic cable from the module.
11. Unplug the terminal block from the module.
12. Remove the module mounting screws (four at top, two at bottom).
13. Disconnect the DC output busbars from the module. Beware not to drop the
screws inside the module!
14. Assemble the module installation stand. See Installing the installation stand for
supply module R8i replacement on page 53. Pay attention to the width: Select
the right braces to match the width of the stand to the width of the cubicle.
15. Fasten the module installation stand to the frame of the cubicle (2 5 screws).
Align the stand and the rails on which the module lies on in the cubicle. Adjust
the height of the feet. Note: Remove the cabinet hinge first if necessary.
WARNING! The feet must lean on a solid floor. The cubicle may topple over when
the heavy module is pulled out if the stand is not supported properly.
16. Fasten the lifting bar of the winch to the two module lifting holes.
WARNING! Before fastening the lifting bar, always ensure that the lifting cable is
tightly wound on the drum of the winch. A slack cable may slip, making the lifting of a
heavy module unstable. A swinging or falling module may cause damage, injury or
even death. See manual ACS800 Liquid-cooled Multidrive and Multidrive Modules
Safety Instructions for more detailed information on safe use of the winch.
17. Pull the module out of cubicle onto the installation stand. Keep the pipes and
wires away from the sharp edges.
18. Winch the module up.
19. Remove the module installation stand.
20. Winch the module down and lay it on a pallet.
WARNING! The module is heavy and its centre of gravity is high. The module
topples over easily. Never manoeuvre it in upright position untied. It is highly
recommended to lay the module on its side before moving the pallet.
21. Move the pallet with the module aside.
22. Before installing a new module, check and service the quick connector through
which the AC output busbars or the cubicle connect to the module:
Check the tightness of the motor cable connections at the quick connector:
70 Nm.
Clean all contact surfaces of the quick connector and apply a layer of suitable
joint compound (e.g. Isoflex Topas NB 52 from Klber Lubrication) onto
them.
23. Install a new module in reverse order.
Maintenance
57
10
Unplugging the fibre optic
cables
11
Unplugging the terminal
block
12
Removing the mounting
screws
16
Fastening the lifting
bar
17
Winching the module
up
18
Removing the
installation stand
13
Disconnecting the
DC busbars
11
10
12
12
12
12
12
12
14
Fastening the
installation stand
15
Pulling the module out
19
Winching the module
down
Maintenance
58
Installing the winch
WARNING! Before fastening the lifting bar to the module, always ensure that the
lifting cable is tightly wound on the drum of the winch. A slack cable may slip, making
the lifting of a heavy module unstable. A swinging or falling module may cause
damage, injury or even death. See ACS800 Liquid-cooled Multidrive and Multidrive
Modules Safety Instructions [3AFE68715318 (English)] for detailed information on
safe use of the winch.
1. Fasten the right-hand side support of the winch to the support frame of the
cubicle (four screws). Fasten the left-hand side support of the winch to the
support frame of the cubicle (four screws). Note: Position the guide pins of the
supports in the holes of the cabinet frame before tightening the screws.
2. Lead the beam (a) through the left and right winch support and the winch body.
Lock the beam with two locking pins (b).
2
b
1
a
b
Do not overtighten!
Max.torque 5.5 Nm.
Ensure that the studs
are in frame holes
when tightening the
screws.
59
General
The cooling system of an ACS800 liquid-cooled drive consists of two circuits: firstly,
the internal cooling circuit that covers the heat-generating electrical components and
transfers the heat to the cooling unit, and the external cooling circuit that is usually
part of a larger external cooling system. This chapter deals with the internal cooling
circuit.
Internal cooling system diagram
The following is a diagram of how the coolant circulates in the supply, inverter and
brake units of a drive system.
The modules in each cubicle can be isolated from the main cooling circuit by closing
the inlet (a) and outlet valves (b). Each cubicle is also equipped with a drain valve (c)
and a bleed valve (d).
Supply
module
A/L
Inverter
module
Inverter modules Brake
chopper
b d
a c a c a c a c
b d b d b d Coolant
OUT
Coolant
IN
A/L = Air to liquid heat exchanger
A/L A/L A/L A/L A/L A/L
60
Connection to a cooling unit
Connection to an ACS800-1007LC cooling unit
Refer to the ACS800-1007LC Cooling Units Users Manual
Connection to a custom cooling unit
General requirements
Equip the system with an expansion tank to damp pressure rise due to volume
changes when the temperature varies. Keep the pressure within the limits specified
in Specifications below. Install a pressure regulator to ensure that the maximum
permissible operating pressure is not exceeded.
The materials used in the cooling system are listed in Specifications on page 63.
Coolant temperature control
The temperature of the coolant in the internal cooling circuit must be kept within the
limits specified in Specifications on page 63. Note that the minimum temperature is
dependent on ambient temperature and relative humidity.
The following diagram shows an example of coolant temperature control using the
three-way valve in the external cooling circuit. Part of the infeed coolant flow is
directed into the return pipe through a three-way valve without letting it circulate in
heat exchanger if the coolant in the internal circuit is too cold.
Installation
Connect the external cooling circuit directly to the coupling flanges on the side of the
drive. Lay liquid piping with extreme care. Secure the pipes properly mechanically
and check for leaks.
Infeed
Bypass valve
TC
Return
Heat
exchanger
External circuit Internal circuit
61
Filling up and bleeding the internal cooling circuit
Both the drive and coolant must be at room temperature before filling in the cooling
circuit. Fill in one cubicle at a time.
WARNING! Ensure that the maximum permissible operating pressure is not
exceeded. When necessary regulate the pressure to appropriate level by draining
excess coolant out of the system.
WARNING! Bleeding of the cooling circuit is very important and has to be done with
great care. Air bubbles in the cooling circuit may reduce or completely block coolant
flow and lead to overheating. Let the air out of the cooling system while filling in
coolant and, e.g. after any power module replacements.
1. Lead the bleed hoses into buckets or other suitable containers. Extend the
standard hoses if necessary.
Note: Draining propylene glycol into the sewer system is not allowed.
2. Open the bleed valves.
3. Fill the circuit with coolant. For coolant specification, see below.
4. When there is a sufficient amount of coolant in the circuit, it will begin to flow from
the bleed hoses. Let some coolant flow out before closing the bleed valves (check
that there are no bubbles visible in the bleed hose).
5. Start the coolant pump.
6. After one to two minutes, stop the pump or block the coolant flow with a valve.
7. Repeat steps 1 to 6 a few times so that all air is let out of the cooling circuit. Listen
for a humming sound and/or feel the piping for vibration to find out if there is still
air left in the circuit.
Adjustments
Set the base pressure to 100150 kPa by draining coolant from the fill/drain
coupling.
Control the coolant temperature so that it stays between the limits stated under
Specifications on page 63.
62
Draining the internal cooling circuit
The internal cooling circuit can be drained through the drain valves in each cubicle.
The power modules in any cubicle can be drained without draining the whole internal
cooling circuit.
Note: Draining propylene glycol into the sewer system is not allowed.
WARNING! High-pressure warm coolant may be present in the internal cooling
circuit. No work on the cooling circuit is allowed until the pressure is lowered down
by stopping the pumps and draining coolant.
1. Lead the bleed and drain hoses to buckets or other suitable containers. Extend
the standard hoses if necessary.
2. Open the bleed valves to let air displace the liquid.
3. If required, dry the piping with compressed oil-free air of less than 6 bar.
4. If the drive is to be stored in temperatures below 0 C (32 F),
dry the cooling circuit with air
fill the cooling circuit with a mixture of water, corrosion inhibitor and DOW
Propylene Glycol according to Freeze protection and corrosion inhibition below.
drain the cooling circuit again.
Adding inhibitor
Add inhibitor in the internal circuit every second year. The amount to be added is
0.5% of the total coolant quantity in the circuit. Use e.g. Cortec VCI-649 (by Cortec
Corporation, www.cortecvci.com).
63
Specifications
Temperature limits
Ambient temperature: See chapter Technical data ACS800-207LC.
Minimum coolant inlet temperature: Condensation is not allowed. The minimum
coolant temperature to avoid condensation (at an atmospheric pressure of 1 bar) is
shown below as a function of the relative humidity () and the ambient
temperature (T
air
).
Maximum coolant inlet temperature for ACS800 liquid-cooled drive
Drive with the optional liquid cooling unit (ACS800-1007LC):
38 C when the drive output capacity is not derated
38 C 45 C when the drive output capacity is derated by 1% per 1 C
temperature increase.
Drive without the optional liquid cooling unit (ACS800-1007LC):
42 C when the drive output capacity is not derated
42 C 48 C when the drive output capacity is derated by 1% per 1 C
temperature increase.
Maximum inlet temperature variation: 4 C
Maximum temperature rise: 13 C; depends on mass flow.
T
air
(C)
Min. T
coolant
(C)
= 95% = 80% = 65% = 50% = 40%
5 4.3 1.9 -0.9 -4.5 -7.4
10 9.2 6.7 3.7 -0.1 -3.0
15 14.2 11.5 8.4 4.6 1.5
20 19.2 16.5 13.2 9.4 6.0
25 24.1 21.4 17.9 13.8 10.5
30 29.1 26.2 22.7 18.4 15.0
35 34.1 31.1 27.4 23.0 19.4
40 39.0 35.9 32.2 27.6 23.8
45 44.0 40.8 36.8 32.1 28.2
50 49.0 45.6 41.6 36.7 32.8
55 53.9 50.4 46.3 42.2 37.1
= Not allowed as standard but the coolant temperature must be 5 C or
above. Consult an ABB representative if operation below coolant
temperature 5 C is required.
Example: At an air temperature of 45 C and relative humidity of 65% the coolant
temperature may not be below +36.8 C
64
Pressure limits
Base pressure: 100150 kPa (recommended); 200 kPa (maximum). Base
pressure denotes the pressure of the system compared with the atmospheric
pressure when the cooling circuit is filled with coolant.
Air counterpressure in the expansion tank: 40 kPa
Maximum design pressure: 600 kPa
Minimum pressure difference: 100 kPa / 120 kPa (hydrostatic)
Maximum pressure difference: 250 kPa
Water quality
Freeze protection and corrosion inhibition
A water-glycol solution is allowed for freeze protection. Corrosion inhibition with
0.5% (vol.) Cortec VCI-649 (by Cortec Corporation, www.cortecvci.com) is required.
The glycol must be pure Dow Propylene Glycol (CAS Number: 57-55-6, available
from The Dow Chemical Company, www.dow.com).
Tap water
The use of tap water is allowed as follows. Tap water must fulfil the requirements of
the Council Directive 98/83/EC of 3/11/98 on the quality of water intended for human
consumption. Corrosion inhibition with 0.5% by volume Cortec VCI-649 is required.
Chloride < 100 mg/l
Sulphate < 200 mg/l
Total dissolved solids no deposits are allowed at the tempera-
ture of +57 C
Maximum particle size < 1 mm
Total hardness as CaCO
3
< 250 mg/l
Conductivity < 400 S/cm (this equals the resistance
of > 2500 ohm/cm)
The water must be clean of solid matter.
65
Glycol concentration
This graph shows the required glycol concentration in weight percentage according
to ambient/storage temperature T.
WARNING! Operation at temperatures below 0 C (32 F) is not permitted even with
antifreeze.
Note: If more than 25% or DOW Propylene Glycol is added, the pressure loss in the
system increases. An operating pressure of more than 150 kPa is required for
sufficient flow.
Materials
Materials used in the internal cooling circuit are listed below. Note: These are also
the only materials that can be used in the external cooling circuit.
stainless steel AISI 316L (UNS 31603)
heavy gauge aluminium
plastic materials such as PA, PEX and Teflon
Note: PVC hoses are not suitable for use with antifreeze.
rubber gasketing NBR (nitrile rubber).
WARNING! If connecting external piping to the internal cooling circuit, use only
materials that are specified above. Copper and brass must not be used under any
circumstances. Even minor dissolution of copper can cause copper precipitation on
aluminium and subsequent galvanic corrosion. The liquid cooling system may not
contain any zinc (e.g. galvanized pipes) at all since zinc would react with the
inhibitor.
0
20
40
60
80
-50 -40 -30 -10 0 -20
T (C)
+5
Glycol concentration% (weight)
66
If the plant incorporates normal iron pipes or cast iron accessories (e.g. motor
housings), a liquid cooling unit with a heat exchanger (such as the ACS800-1007LC)
must be used to separate the systems.
67
This chapter contains the technical data for the cabinet-installed IGBT supply units
ACS800-207LC.
Ratings
Ratings with 50 Hz and 60 Hz supplies.
IGBT Supply Unit
Type
Basic module
ACS800-104LC
Frame
size
No overload use Light overload use Heavy-duty use
I
contmax
I
contmax
I
max
S
N
P
contmax
I
n
P
N
I
hd
P
hd
A AC A DC A DC kVA kW DC A DC kW A DC kW
U
N
=400 V (Range 380415 V)
ACS800-207LC-0240-3 -0240-3 R8i 341 413 471 245 243 397 233 309 181
ACS800-207LC-0330-3 -0330-3 R8i 454 550 627 326 323 528 310 411 241
ACS800-207LC-0410-3 -0410-3 R8i 567 687 784 408 403 660 387 514 302
ACS800-207LC-0540-3 -0540-3 R8i 756 917 1046 543 538 880 516 686 402
ACS800-207LC-0820-3 -0470-3+E205 2R8i 1134 1375 1568 815 807 1320 775 1028 604
ACS800-207LC-1070-3 -0620-3+E205 2R8i 1482 1797 2049 1065 1054 1725 1012 1344 789
ACS800-207LC-1580-3 -0620-3+E205 3R8i 2200 2667 3042 1581 1565 2560 1503 1995 1171
ACS800-207LC-2090-3 -0620-3+E205 4R8i 2903 3520 4015 2087 2066 3379 1983 2633 1545
ACS800-207LC-3100-3 -0620-3+E205 6R8i 4309 5225 5960 3097 3066 5016 2944 3908 2294
U
N
=500 V (Range 380500 V)
ACS800-207LC-0280-5 -0280-5 R8i 324 393 475 281 278 377 267 294 208
ACS800-207LC-0370-5 -0370-5 R8i 432 524 633 374 370 503 356 392 277
ACS800-207LC-0470-5 -0470-5 R8i 540 655 792 468 463 629 444 490 346
ACS800-207LC-0620-5 -0620-5 R8i 720 873 1056 624 617 838 593 653 462
ACS800-207LC-0940-5 -0550-5+E205 2R8i 1080 1309 1584 935 926 1257 889 980 693
ACS800-207LC-1220-5 -0730-5+E205 2R8i 1411 1711 2069 1222 1210 1643 1162 1280 905
ACS800-207LC-1810-5 -0730-5+E205 3R8i 2095 2540 3072 1814 1796 2439 1724 1900 1344
ACS800-207LC-2390-5 -0730-5+E205 4R8i 2765 3352 4054 2394 2370 3218 2276 2508 1773
ACS800-207LC-3550-5 -0730-5+E205 6R8i 4104 4976 6017 3554 3519 4777 3378 3722 2632
U
N
=690 V (Range 525690 V)
ACS800-207LC-0260-7 -0260-7 R8i 216 262 327 258 256 251 245 196 191
ACS800-207LC-0360-7 -0360-7 R8i 300 364 453 359 355 349 341 272 266
ACS800-207LC-0430-7 -0430-7 R8i 360 436 544 430 426 419 409 327 319
ACS800-207LC-0570-7 -0570-7 R8i 480 582 726 574 568 559 545 435 425
ACS800-207LC-0860-7 -0550-7+E205 2R8i 720 873 1088 860 852 838 818 653 637
ACS800-207LC-1120-7 -0700-7+E205 2R8i 941 1141 1422 1124 1113 1095 1069 853 833
ACS800-207LC-1670-7 -0700-7+E205 3R8i 1397 1694 2111 1669 1653 1626 1587 1267 1236
ACS800-207LC-2200-7 -0700-7+E205 4R8i 1843 2235 2786 2203 2181 2145 2094 1672 1631
ACS800-207LC-3270-7 -0700-7+E205 6R8i 2736 3317 4136 3270 3237 3185 3108 2481 2421
ACS800-207LC-4360-7 -0700-7+E205 8R8i 3648 4423 5514 4360 4316 4246 4144 3309 3228
ACS800-207LC-4900-7 -0700-7+E205 9R8i 4104 4976 6204 4905 4856 4777 4661 3722 3632
ACS800-207LC-5450-7 -0700-7+E205 10R8i 4560 5529 6893 5450 5395 5308 5179 4136 4036
00430970.xls C-20
68
Symbols
Derating
The load capacity (current and power) decreases if the installation site altitude exceeds 1000 metres
(3281 ft), or if the ambient temperature exceeds 45 C (104 F).
Temperature derating
In the ambient temperature range +45 C (+113 F) to +55 C (+131 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 5 C =
95% or 0.95. The output current is then 0.95 I
2N
or 0.95 I
cont.max
.
Altitude derating
At altitudes from 1000 to 4000 m (3281 to 13123 ft) above sea level, the derating is 0.5% for every
100 m (328 ft). For a more accurate derating, use the DriveSize PC tool.
Nominal ratings (no overload use)
I
cont.max
Continuous RMS input (AC) and output (DC) current. No overloadability at 40 C.
I
max
Maximum output current (DC). Allowable for 10 seconds at start, otherwise as long as allowed by drive
temperature.
S
N
Apparent power
P
cont.max
Active power
Ratings for light-overload use (10% overloadability)
I
2N
Continuous rms current. 10% overload is allowed for 1 minute every 5 minutes.
P
N
Active power, light overload use
Ratings for heavy-duty use (50% overloadability)
I
2hd
P
hd
Active power, heavy-duty use
%
C
69
Auxiliary circuit current consumption
The table below shows the current consumption of the main components in the
auxiliary circuit. See also Connection of external power supply for the auxiliary
circuits in page 39 for instructions.
Losses, coolant flow and quantity
See chapter Technical data ACS800-104LC modules.
Internal cooling circuit data
Fuses
Device/load Current consumption [A]
1~230 V / 50 Hz
Supply
1~230 V / 60 Hz
Supply
1~115 V / 60 Hz
Supply
1)
Note
IGBT Supply Unit and options
24 V DC power supply (U10) for boards and relays 1.3 1.3 2.5
-
Fan of IGBT supply module (Y41.1) 1.3 1.5 2.8
2)
Control relays (breaker control, charging relays,etc.) 0.5 0.5 1.0
3)
Fan in incoming cubicle (Y11.1Y14.1) 0.4 0.5 0.7
5)
Fan in auxiliary control cubicle 0.4 0.5 0.7
4)
Inverter unit and options
-
Fan of inverter module (Y41.1) 0.8 1.0 2.0
2)
Prevention of unexpected start circuit (per module) 0.4 0.4 0.8
6)
Cooling unit
24 V DC power supply, and control relays See ACS800-1007LC Users Manual
Notes:
1) Only with option +G304 (115 VAC control voltage)
2) There is one fan per supply or inverter module.
3) There is one control circuit per breaker (or contactor). Note that the drive always supplies the breaker control circuit
despite of the location of the breaker.
4) Only with option +G344. The figure and option code are valid for ACS800-207LC (cabinet-built supply unit).
5) Only with option +F255 or +F250. There is one fan in 400 mm and 600 mm wide cubicles and two fans in 1000 mm
wide cubicle. The figure and option code are valid for ACS800-207LC (cabinet-built supply unit).
6) Only with option +Q950.
70
Input busbar and cable lead-through data
The data is divided into subsections according to number and size of supply
modules used. For the usage of modules in each drive type, see the section Ratings
on page 67.
Units with built-in main breaker (option +F255)
The cables enter the breaker cubicle.
Input power connection
Output power connection
Degree of protection
IP42; IP54
Supply
modules
No. of busbars Screw size
Tightening
torque
Cable lead-
throughs
400V / 500V / 690V
1R8i 6 / 6 / 6 M12 () 70 Nm (50 lb.ft) 18 60 mm
2R8i 6 / 6 / 6 M12 () 70 Nm (50 lb.ft) 18 60 mm
3R8i 9 / 9 / 6 M12 (") 70 Nm (50 lb.ft) 18 60 mm
4R8i 9 / 9 / 6 M12 () 70 Nm (50 lb.ft) 18 60 mm
6R8i 9 / 9 / 9 M12 () 70 Nm (50 lb.ft) 18 60 mm
1)
Dimensions of input terminal in
600 mm breaker cubicle
2)
Dimensions of input busbar in
1000 mm breaker cubicle
71
Ambient conditions
Materials
See page 83.
Standards and markings
See ACS800 Liquid-cooled Multidrive and ACS800 Multidrive Modules Planning the
Electrical Installation [3AFE68715423 (English)].
Environmental limits for the drive are given below. The drive must be used in a heated,
indoor controlled environment.
Operation
installed for stationary use
Storage
in the protective package
Transportation
in the protective package
Installation site altitude 0 to 4000 m (13123 ft) above
sea level [above 1000 m
(3281 ft), see Derating on
page 68]
- -
Air temperature 0+55 C (+32+131 F)
[above +45 C (+113 F),
see Derating on page 68]
-40+70 C (-40 to +158 F) -40+70 C (-40 to +158 F)
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
(IEC60721-3-3, IEC60721-3-2,
IEC60721-3-1)
No conductive dust allowed.
Boards with coating:
Chemical gases: Class 3C2
Solid particles: Class 3S2
Atmospheric pressure 70 to 106 kPa
0.7 to 1.05 atmospheres
70 to 106 kPa
60 to 106 kPa
Vibration Marine requirements
1 mm (peak value,
213.2 Hz)
0.7g (13.2 - 100 Hz)
Max. amplification 10
IEC 60068-2-6
0,075 mm (058 Hz)
10 m/s
2
(58150 Hz)
Max. amplification 10
1M2, IEC 60721-3-1
1.5 mm (29 Hz)
5 m/s
2
(9200 Hz)
2M2, IEC 60721-3-2
3,5 mm (29 Hz)
10 m/s
2
(9200 Hz)
Random 10-200 Hz,
acceleration spectral density
1 m
2
/s
3
Shock (IEC 60068-2-29) Not allowed Max. 100 m/s
2
(330 ft./s
2
),
11 ms
Max. 100 m/s
2
(330 ft./s
2
),
11 ms
Free fall Not allowed 100 mm (4 in.) for weight
over 100 kg (220 lb.)
100 mm (4 in.) for weight
over 100 kg (220 lb.)
72
US patents
See ACS800 Liquid-cooled Multidrive and ACS800 Multidrive Modules Planning the
Electrical Installation [3AFE68715423 (English)].
73
This chapter contains the technical data for IGBT supply modules ACS800-104LC.
Ratings
Supply module
type
No overload use Light overload use Heavy-duty use
I
contmaxAC
I
contmaxDC
I
max
S
N
P
contmax
I
n
P
N
I
hd
P
hd
A (AC) A (DC) A (DC) kVA kW (DC) A (DC) kW A (DC) kW
U
N
= 400 V (380415 V)
ACS800-104LC-0310-3+E205 341 413 471 245 243 397 233 309 181
ACS800-104LC-0390-3+E205 454 550 627 326 323 528 310 411 241
ACS800-104LC-0470-3+E205 567 687 784 408 403 660 387 514 302
ACS800-104LC-0620-3+E205 756 917 1046 543 538 880 516 686 402
ACS800-104LC-0920-3+E205 1134 1375 1568 815 807 1320 775 1028 604
ACS800-104LC-1210-3+E205 1482 1797 2049 1065 1054 1725 1012 1344 789
ACS800-104LC-1790-3+E205 2200 2667 3042 1581 1565 2560 1503 1995 1171
ACS800-104LC-2370-3+E205 2903 3520 4015 2087 2066 3379 1983 2633 1545
ACS800-104LC-3510-3+E205 4309 5225 5960 3097 3066 5016 2944 3908 2294
U
N
= 500 V (380500 V)
ACS800-104LC-0330-5+E205 324 393 475 281 278 377 267 294 208
ACS800-104LC-0470-5+E205 432 524 633 374 370 503 356 392 277
ACS800-104LC-0550-5+E205 540 655 792 468 463 629 444 490 346
ACS800-104LC-0730-5+E205 720 873 1056 624 617 838 593 653 462
ACS800-104LC-1070-5+E205 1080 1309 1584 935 926 1257 889 980 693
ACS800-104LC-1430-5+E205 1411 1711 2069 1222 1210 1643 1162 1280 905
ACS800-104LC-2120-5+E205 2095 2540 3072 1814 1796 2439 1724 1900 1344
ACS800-104LC-2790-5+E205 2765 3352 4054 2394 2370 3218 2276 2508 1773
ACS800-104LC-4150-5+E205 4104 4976 6017 3554 3519 4777 3378 3722 2632
U
N
= 690 V (525690 V)
ACS800-104LC-0310-7+E205 216 262 327 258 256 251 245 196 191
ACS800-104LC-0480-7+E205 300 364 453 359 355 349 341 272 266
ACS800-104LC-0550-7+E205 360 436 544 430 426 419 409 327 319
ACS800-104LC-0700-7+E205 480 582 726 574 568 559 545 435 425
ACS800-104LC-1070-7+E205 720 873 1088 860 852 838 818 653 637
ACS800-104LC-1370-7+E205 941 1141 1422 1124 1113 1095 1069 853 833
ACS800-104LC-2030-7+E205 1397 1694 2111 1669 1653 1626 1587 1267 1236
ACS800-104LC-2680-7+E205 1843 2235 2786 2203 2181 2145 2094 1672 1631
ACS800-104LC-3970-7+E205 2736 3317 4136 3270 3237 3185 3108 2481 2421
ACS800-104LC-5300-7+E205 3648 4423 5514 4360 4316 4246 4144 3309 3228
ACS800-104LC-5960-7+E205 4104 4976 6204 4905 4856 4777 4661 3722 3632
ACS800-104LC-6620-7+E205 4560 5529 6893 5450 5395 5308 5179 4136 4036
00430970.XLS / C.24
74
Symbols
Derating
The load capacity (current and power) decreases if the installation site altitude exceeds 1000 metres
(3281 ft), or if the ambient temperature exceeds 45 C (104 F).
Temperature derating
In the ambient temperature range +45 C (+113 F) to +55 C (+131 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 5 C =
95% or 0.95. The output current is then 0.95 I
2N
or 0.95 I
cont.max
.
Altitude derating
At altitudes from 1000 to 4000 m (3281 to 13123 ft) above sea level, the derating is 0.5% for every
100 m (328 ft).
No-overload use
I
cont.max
Continuous RMS input (AC) and output (DC) currents. No overloadability at 40 C.
I
max
Maximum output current. Allowable for 10 seconds at start, otherwise as long as allowed by drive
temperature.
S
N
Nominal apparent power
P
cont.max
Active power (output power)
Light-overload use (10% overloadability)
I
n
P
N
Typical ratings for heavy-duty use (50% overloadability)
I
hd
P
hd
%
C
75
Type equivalence table and frame sizes
1)
Multiplier denotes the number of basic supply modules connected in parallel
Supply module type Supply unit type
(cabinet-installed)
Basic supply module type Basic supply module
frame size
1)
U
N
= 400 V (380415 V)
ACS800-104LC-0310-3+E205 ACS800-207LC-0240-3 - R8i
ACS800-104LC-0390-3+E205 ACS800-207LC-0330-3 - R8i
ACS800-104LC-0470-3+E205 ACS800-207LC-0410-3 - R8i
ACS800-104LC-0620-3+E205 ACS800-207LC-0540-3 - R8i
ACS800-104LC-0920-3+E205 ACS800-207LC-0820-3 ACS800-104LC-0470-3+E205 2R8i
U
N
= 500 V (380500 V)
ACS800-104LC-0330-5+E205 ACS800-207LC-0280-5 - R8i
ACS800-104LC-0470-5+E205 ACS800-207LC-0370-5 - R8i
ACS800-104LC-0550-5+E205 ACS800-207LC-0470-5 - R8i
ACS800-104LC-0730-5+E205 ACS800-207LC-0620-5 - R8i
U
N
= 690 V (525690 V)
ACS800-104LC-0310-7+E205 ACS800-207LC-0260-7 - R8i
ACS800-104LC-0480-7+E205 ACS800-207LC-0360-7 - R8i
ACS800-104LC-0550-7+E205 ACS800-207LC-0430-7 - R8i
ACS800-104LC-0700-7+E205 ACS800-207LC-0570-7 - R8i
00430970.XLS / C.24
76
Auxiliary circuit current consumption
The table below shows the current consumption of the main components in the
auxiliary circuit. See also Connection of external power supply for the auxiliary
circuits in page 39 for instructions.
Device/load Current consumption [A]
1~230 V / 50 Hz
Supply
1~230 V / 60 Hz
Supply
1~115 V / 60 Hz
Supply
1)
Note
IGBT supply unit and options
-
Fan of IGBT supply module (Y41.1) 1.3 1.5 2.8
2)
Control relays (breaker control, charging relays,etc.)
3)
Inverter unit and options
-
Fan of inverter module (Y41.1) 0.8 1.0 2.0
2)
Prevention of unexpected start circuit (per module) 0.4 0.4 0.8
4)
Cooling unit
24 V DC power supply, and control relays See ACS800-1007LC Users Manual
Notes:
1) Only with option +G304 (115 VAC control voltage)
2) There is one fan per supply or inverter module.
3) Customer-specific.
4) Only with option +Q950.
77
LCL filter types, data and use with supply modules
Supply module
type
LCL filter
type
L1 L2 C
Ind. Weight loss Ind. Weight loss Cap. Weight loss
[microH] [kg] [kW] [microH] [kg] [kW] [microF] [kg] [kW]
U
N
= 400 V (380415 V) 0.1
ACS800-104LC-0310-3+E205 ALCL-12LC-5 108 120 1.0 162 121 1.7 63 4.7 0.3
ACS800-104LC-0390-3+E205 ALCL-13LC-5 81 125 1.1 122 125 1.7 83 5.6 0.3
ACS800-104LC-0470-3+E205 ALCL-14LC-5 65 135 1.1 97 131 2.0 104 6.6 0.3
ACS800-104LC-0620-3+E205 ALCL-15LC-5 49 130 1.3 73 157 2.4 139 9.8 0.4
ACS800-104LC-0920-3+E205 ALCL-24LC-5 32 140 2.1 49 177 3.0 209 13.9 0.5
ACS800-104LC-1210-3+E205 ALCL-25LC-5 25 140 3.8 45 225 3.4 273 19.4 0.7
ACS800-104LC-1790-3+E205 3ALCL-15LC-5 16 390 3.9 24 471 7.1 417 29.4 1.1
ACS800-104LC-2370-3+E205 2ALCL-25LC-5 13 280 7.6 23 450 6.8 546 38.8 1.4
ACS800-104LC-3510-3+E205 3ALCL-25LC-5 8 420 11.4 15 675 10.2 819 58.2 2.2
U
N
= 500 V (380500 V)
ACS800-104LC-0330-5+E205 ALCL-12LC-5 108 120 1.0 162 121 1.7 63 4.7 0.3
ACS800-104LC-0470-5+E205 ALCL-13LC-5 81 125 1.1 122 125 1.7 83 5.6 0.3
ACS800-104LC-0550-5+E205 ALCL-14LC-5 65 135 1.1 97 131 2.0 104 6.6 0.3
ACS800-104LC-0730-5+E205 ALCL-15LC-5 49 130 1.3 73 157 2.4 139 9.8 0.4
ACS800-104LC-1070-5+E205 ALCL-24LC-5 32 140 2.1 49 177 3.0 209 13.9 0.5
ACS800-104LC-1430-5+E205 ALCL-25LC-5 25 140 3.8 45 225 3.4 273 19.4 0.7
ACS800-104LC-2120-5+E205 3ALCL-15LC-5 16 390 3.9 24 471 7.1 417 29.4 1.1
ACS800-104LC-2790-5+E205 2ALCL-25LC-5 13 280 7.6 23 450 6.8 546 38.8 1.4
ACS800-104LC-4150-5+E205 3ALCL-25LC-5 8 420 11.4 15 675 10.2 819 58.2 2.2
U
N
= 690 V (525690 V)
ACS800-104LC-0310-7+E205 ALCL-12LC-7 235 120 0.8 352 121 1.6 29 4.7 0.2
ACS800-104LC-0480-7+E205 ALCL-13LC-7 169 120 1.1 254 120 1.7 40 6.2 0.3
ACS800-104LC-0550-7+E205 ALCL-14LC-7 141 120 1.2 211 120 1.9 48 7.2 0.3
ACS800-104LC-0700-7+E205 ALCL-15LC-7 106 140 1.3 159 130 2.1 64 9.8 0.3
ACS800-104LC-1070-7+E205 ALCL-24LC-7 70 130 1.7 106 155 2.3 96 14.0 0.4
ACS800-104LC-1370-7+E205 ALCL-25LC-7 54 130 2.4 97 185 3.7 125 16.2 0.6
ACS800-104LC-2030-7+E205 ALCL-35LC-7 36 190 3.0 65 286 3.7 186 24.4 0.7
ACS800-104LC-2680-7+E205 2ALCL-25LC-7 27 260 4.8 49 370 7.4 250 32.4 1.2
ACS800-104LC-3970-7+E205 2ALCL-35LC-7 18 380 6 33 572 7.4 372 48.8 1.3
ACS800-104LC-5300-7+E205 4ALCL-25LC-7 14 520 9.6 24 740 14.8 500 64.8 2.4
ACS800-104LC-5960-7+E205 3ALCL-35LC-7 12 570 9 22 858 11.1 558 73.2 2.0
ACS800-104LC-6620-7+E205 5ALCL-25LC-7 11 650 12.0 19 925 18.5 625 81.0 3.1
00430970.XLS / C.24
78
Supply module capacitances
Supply module type Capacitance
[mF]
U
N
= 400 V (380415 V)
ACS800-104LC-0310-3+E205 10.3
ACS800-104LC-0390-3+E205 14.4
ACS800-104LC-0470-3+E205 16.4
ACS800-104LC-0620-3+E205 20.5
ACS800-104LC-0920-3+E205 32.8
ACS800-104LC-1210-3+E205 41.0
ACS800-104LC-1790-3+E205 61.5
ACS800-104LC-2370-3+E205 82.0
ACS800-104LC-3510-3+E205 123.0
U
N
= 500 V (380500 V)
ACS800-104LC-0330-5+E205 10.3
ACS800-104LC-0470-5+E205 14.4
ACS800-104LC-0550-5+E205 16.4
ACS800-104LC-0730-5+E205 20.5
ACS800-104LC-1070-5+E205 32.8
ACS800-104LC-1430-5+E205 41.0
ACS800-104LC-2120-5+E205 61.5
ACS800-104LC-2790-5+E205 82.0
ACS800-104LC-4150-5+E205 123.0
U
N
= 690 V (525690 V)
ACS800-104LC-0310-7+E205 6.1
ACS800-104LC-0480-7+E205 7.7
ACS800-104LC-0550-7+E205 9.2
ACS800-104LC-0700-7+E205 10.7
ACS800-104LC-1070-7+E205 18.4
ACS800-104LC-1370-7+E205 21.5
ACS800-104LC-2030-7+E205 32.2
ACS800-104LC-2680-7+E205 42.9
ACS800-104LC-3970-7+E205 64.4
ACS800-104LC-5300-7+E205 85.9
ACS800-104LC-5960-7+E205 96.6
ACS800-104LC-6620-7+E205 107.3
00430970.XLS / C.24
79
Losses, coolant flow and quantity
Supply module type Losses Cooling media Efficiency
P
lossISU
P
lossLCL
P
loss tot
P
loss_C
P
loss_A
Liquid
qty.
Massflow Pressure
loss
1)
[kW] [kW] [kW] [kW] [kW] [l] [l/min] [kPa] [%]
U
N
= 400 V (380415 V)
ACS800-104LC-0310-3+E205 4.4 3.0 7.4 7.2 0.1 7.8 32 100 97.0%
ACS800-104LC-0390-3+E205 5.6 3.1 8.7 8.5 0.2 7.8 32 100 97.4%
ACS800-104LC-0470-3+E205 6.7 3.4 10.1 9.9 0.2 7.8 32 100 97.6%
ACS800-104LC-0620-3+E205 8.9 4.0 12.9 12.6 0.3 8.6 32 100 97.7%
ACS800-104LC-0920-3+E205 13.5 5.6 19.1 18.7 0.4 11.1 53 100 97.7%
ACS800-104LC-1210-3+E205 17.3 7.9 25.3 24.8 0.5 11.1 53 100 97.7%
ACS800-104LC-1790-3+E205 25.7 12.0 37.8 37.0 0.8 19.2 84 100 97.6%
ACS800-104LC-2370-3+E205 33.8 15.8 49.7 48.7 1.0 18.9 100 100 97.7%
ACS800-104LC-3510-3+E205 50.1 23.8 73.9 72.4 1.5 27.4 147 100 97.6%
U
N
= 500 V (380500 V)
ACS800-104LC-0330-5+E205 4.5 3.0 7.5 7.3 0.1 7.8 32 100 97.4%
ACS800-104LC-0470-5+E205 5.7 3.1 8.8 8.6 0.2 7.8 32 100 97.7%
ACS800-104LC-0550-5+E205 6.8 3.4 10.2 10.0 0.2 7.8 32 100 97.8%
ACS800-104LC-0730-5+E205 9.0 4.0 13.0 12.8 0.3 8.6 32 100 97.9%
ACS800-104LC-1070-5+E205 13.7 5.6 19.3 18.9 0.4 11.1 53 100 98.0%
ACS800-104LC-1430-5+E205 17.6 7.9 25.5 25.0 0.5 11.1 53 100 97.9%
ACS800-104LC-2120-5+E205 26.1 12.0 38.2 37.4 0.8 19.2 84 100 97.9%
ACS800-104LC-2790-5+E205 34.3 15.8 50.2 49.2 1.0 18.9 100 100 97.9%
ACS800-104LC-4150-5+E205 50.9 23.8 74.6 73.1 1.5 27.4 147 100 97.9%
U
N
= 690 V (525690 V)
ACS800-104LC-0310-7+E205 5.0 2.6 7.6 7.4 0.2 7.8 32 100 97.1%
ACS800-104LC-0480-7+E205 5.6 3.1 8.7 8.5 0.2 7.8 32 100 97.6%
ACS800-104LC-0550-7+E205 7.6 3.4 11.0 10.8 0.2 7.8 32 100 97.5%
ACS800-104LC-0700-7+E205 8.3 3.7 12.0 11.8 0.2 7.8 32 100 97.9%
ACS800-104LC-1070-7+E205 15.2 4.4 19.6 19.2 0.4 11.1 53 100 97.8%
ACS800-104LC-1370-7+E205 16.2 6.7 22.9 22.5 0.5 11.1 53 100 98.0%
ACS800-104LC-2030-7+E205 24.1 7.4 31.5 30.8 0.6 14.6 77 100 98.1%
ACS800-104LC-2680-7+E205 31.8 13.4 45.2 44.3 0.9 18.9 100 100 98.0%
ACS800-104LC-3970-7+E205 47.2 14.7 61.9 60.7 1.2 25.9 148 100 98.1%
ACS800-104LC-5300-7+E205 62.9 26.8 89.7 87.9 1.8 37.0 200 100 98.0%
ACS800-104LC-5960-7+E205 70.8 22.1 92.9 91.0 1.9 39.7 225 100 98.1%
ACS800-104LC-6620-7+E205 78.6 33.6 112.2 109.9 2.2 44.8 247 100 98.0%
00430970.XLS / C.24
P
lossISU
Power loss of supply module(s)
P
lossLCL
Power loss of supply LCL filter
P
loss tot
Sum of P
lossISU
and P
lossLCL
P
loss_C
Power loss conducted to coolant
P
loss_A
Power loss emitted to air (ambient space)
1) Hydrostatic pressure loss is 120 kPa due to 2 m height difference between the inlet and outlet pipe of the cabinet line up
80
AC fuses
1)
UL recognized
2)
Not UL recognized (by the time of publishing this manual)
3)
UL recognized USA & Canada
Supply module
ACS800-104LC
Basic module
ACS800-104LC
AC fuse information
Type by Ferraz
Shawmut
Type byt
Bussman
ABB factory
code
In [A] Qty
U
N
=400 V (Range 380-415 V)
-0310-3+E205 -0310-3+E205 6,6URD31TTF0550
1)
170M5411
1)
68731631 550 3
-0390-3+E205 -0390-3+E205 6,6URD32TTF0700
1)
170M5413
1)
68752493 700 3
-0470-3+E205 -0470-3+E205 6,6URD32TTF0900
1)
170M5415
1)
68752540 900 3
-0620-3+E205 -0620-3+E205 6,6URD33TTF1250
1)
170M7059
1)
68704227 1250 3
-0920-3+E205 -0470-3+E205 7,5URD44TQF2000
2)
170M7062
1)
68689589 2000 3
-1210-3+E205 -0620-3+E205 7URD44TQF2500
3)
170M7063
1)
68752591 2500 3
-1790-3+E205 -0620-3+E205 6,6URD33TTF1250
1)
170M7059
1)
68704227 1250 9
-2370-3+E205 -0620-3+E205 7URD44TQF2500
3)
170M7063
1)
68752591 2500 6
-3510-3+E205 -0620-3+E205 7URD44TQF2500
3)
170M7063
1)
68752591 2500 9
U
N
=500 V (Range 380-500 V)
-0380-5+E205 -0380-5+E205 6,6URD31TTF0550
1)
170M5411
1)
68731631 550 3
-0470-5+E205 -0470-5+E205 6,6URD32TTF0700
1)
170M5413
1)
68752493 700 3
-0550-5+E205 -0550-5+E205 6,6URD32TTF0900
1)
170M5415
1)
68752540 900 3
-0730-5+E205 -0730-5+E205 6,6URD33TTF1250
1)
170M7059
1)
68704227 1250 3
-1070-5+E205 -0550-5+E205 7,5URD44TQF2000
2)
170M7062
1)
68689589 2000 3
-1430-5+E205 -0730-5+E205 7URD44TQF2500
3)
170M7063
1)
68752591 2500 3
-2120-5+E205 -0730-5+E205 6,6URD33TTF1250
1)
170M7059
1)
68704227 1250 9
-2790-5+E205 -0730-5+E205 7URD44TQF2500
3)
170M7063
1)
68752591 2500 6
-4150-5+E205 -0730-5+E205 7URD44TQF2500
3)
170M7063
1)
68752591 2500 9
U
N
=690 V (Range 525-690 V)
-0310-7+E205 -0310-7+E205 6,6URD31TTF0350
1)
170M4411
1)
68731615 350 3
-0480-7+E205 -0480-7+E205 6,6URD31TTF0450
1)
170M4413
1)
68731623 450 3
-0550-7+E205 -0550-7+E205 6,6URD31TTF0550
1)
170M5411
1)
68731631 550 3
-0700-7+E205 -0700-7+E205 6,6URD32TTF0700
1)
170M5413
1)
68752493 700 3
-1070-7+E205 -0550-7+E205 6,6URD33TTF1250
1)
170M7059
1)
68704227 1250 3
-1370-7+E205 -0700-7+E205 6,6URD33TTF1400
1)
170M7060
1)
68689571 1400 3
-2030-7+E205 -0700-7+E205 7,5URD44TQF2000
2)
170M7062
1)
68689589 2000 3
-2680-7+E205 -0700-7+E205 6,6URD33TTF1400
1)
170M7060
1)
68689571 1400 6
-3970-7+E205 -0700-7+E205 7,5URD44TQF2000
2)
170M7062
1)
68689589 2000 6
-5300-7+E205 -0700-7+E205 6,6URD33TTF1400
1)
170M7060
1)
68689571 1400 12
-5960-7+E205 -0700-7+E205 7,5URD44TQF2000
2)
170M7062
1)
68689589 2000 9
-6620-7+E205 -0700-7+E205 6,6URD33TTF1400
1)
170M7060
1)
68689571 1400 15
00430970.XLS / C.32
81
DC fuses
1)
UL recognized
Supply module
ACS800-104LC
Basic module
ACS800-104LC
DC fuse information
Type by Ferraz
Shawmut
Type by
Bussman
ABB factory
code
I
n
[A] Qty
U
N
= 400 V (380415 V)
-0310-3+E205 -0310-3+E205 6,9URD33TTF0800
1)
170M6412
1)
68731640 800 2
-0390-3+E205 -390-3+E205 6,9URD33TTF1100
1)
170M6415
1)
68731658 1100 2
-0470-3+E205 -0470-3+E205 6,9URD33TTF1100
1)
170M6415
1)
68731658 1100 2
-0620-3+E205 -0620-3+E205 6,9URD73TTF1600
1)
170M6419
1)
68393108 1600 2
-0920-3+E205 -0470-3+E205 6,9URD33TTF1100
1)
170M6415
1)
68731658 1100 4
-1210-3+E205 -0620-3+E205 6,9URD73TTF1600
1)
170M6419
1)
68393108 1600 4
-1790-3+E205 -0620-3+E205 6,9URD73TTF1600
1)
170M6419
1)
68393108 1600 6
-2370-3+E205 -0620-3+E205 6,9URD73TTF1600
1)
170M6419
1)
68393108 1600 8
-3510-3+E205 -0620-3+E205 6,9URD73TTF1600
1)
170M6419
1)
68393108 1600 12
U
N
= 500 V (380500 V)
-0380-5+E205 -0380-5+E205 6,9URD33TTF0800
1)
170M6412
1)
68731640 800 2
-0470-5+E205 -0470-5+E205 6,9URD33TTF1100
1)
170M6415
1)
68731658 1100 2
-0550-5+E205 -0550-5+E205 6,9URD33TTF1100
1)
170M6415
1)
68731658 1100 2
-0730-5+E205 -0730-5+E205 6,9URD73TTF1600
1)
170M6419
1)
68393108 1600 2
-1070-5+E205 -0550-5+E205 6,9URD33TTF1100
1)
170M6415
1)
68731658 1100 4
-1430-5+E205 -0730-5+E205 6,9URD73TTF1600
1)
170M6419
1)
68393108 1600 4
-2120-5+E205 -0730-5+E205 6,9URD73TTF1600
1)
170M6419
1)
68393108 1600 6
-2790-5+E205 -0730-5+E205 6,9URD73TTF1600
1)
170M6419
1)
68393108 1600 8
-4150-5+E205 -0730-5+E205 6,9URD73TTF1600
1)
170M6419
1)
68393108 1600 12
U
N
= 690 V (525690 V)
-0310-7+E205 -0310-7+E205 12,5URD73TTF0450
1)
170M6541
1)
68735971 450 2
-0480-7+E205 -0480-7+E205 12,5URD73TTF0700
1)
170M6545
1)
68735980 700 2
-0550-7+E205 -0550-7+E205 12,5URD73TTF0800
1)
170M6546
1)
68736005 800 2
-0700-7+E205 -0700-7+E205 10URD73TTF1100
1)
170M6549 68736021 1100 2
-1070-7+E205 -0550-7+E205 12,5URD73TTF0800
1)
170M6546
1)
68736005 800 4
-1370-7+E205 -0700-7+E205 10URD73TTF1100
1)
170M6549 68736021 1100 4
-2030-7+E205 -0700-7+E205 10URD73TTF1100
1)
170M6549 68736021 1100 6
-2680-7+E205 -0700-7+E205 10URD73TTF1100
1)
170M6549 68736021 1100 8
-3970-7+E205 -0700-7+E205 10URD73TTF1100
1)
170M6549 68736021 1100 12
-5300-7+E205 -0700-7+E205 10URD73TTF1100
1)
170M6549 68736021 1100 16
-5960-7+E205 -0700-7+E205 10URD73TTF1100
1)
170M6549 68736021 1100 18
-6620-7+E205 -0700-7+E205 10URD73TTF1100
1)
170M6549 68736021 1100 20
00430970.XLS / C.32
82
Output connection
Degree of protection
IP00
Ambient conditions
See page 71.
Input power connection
Voltage 380/400/415 V AC 3-phase for 415 V AC units
380/400/415/440/460/480/500 V AC 3-phase for 500 V AC units
525/550/575/600/660/690 VAC 3-phase for 690 VAC units
10% variation from converter nominal voltage is allowed as default. See also item Voltage
dips below.
Frequency 50 2 Hz or 60 2 Hz. Maximum rate of change 17%/s.
Rated short-time withstand
current I
cw ,
1s (IEC 60439-1,
UL508C)
50 kA: - cabinet-installed supply unit (ACS800-207LC) with grounding switch (option
+F249)
65 kA: - supply module (ACS800-104LC) equipped with the AC fuses specified by ABB
- cabinet-installed supply unit (ACS800-207LC) without grounding switch (no option
+F249)
US and Canada: The cabinet-installed supply unit (ACS800-207LC) which is not equipped
with a grounding switch (no option +F249) is suitable for use on a circuit capable of
delivering not more than 65,000 symmetrical amperes (rms) at 600 V maximum.
Power factor 1.00 (in normal use)
Harmonic distortion Total harmonic current distortion (n = 2...40) < 5%.
Total harmonic voltage distortion (n = 2...40) < 5%, when R
sc
> 7.
Voltage dips
Switching frequency 3 kHz (typical, may vary in between 3 kHz 2 kHz based on temperature model
Nominal voltage 537 V DC 587 V DC 10%
622 V DC (537 V DC) 707 V DC 10%
746 V DC 980 V DC 10%
DC voltage limits Overvoltage: 130% of U
1max
;
Undervoltage: 60% of U
1min
(min. nominal voltage for the unit)
100
80
60
40
20
1 2 3 4 5
t [s]
V [% of nominal input voltage]
Shaded area represents the allowed
input voltage dip
0
83
Materials
Tightening torques for power connections
Applicable standards
See ACS800 Liquid-cooled Multidrive and Multidrive Modules Planning the Electrical
Markings
US patents
Cabinet Hot-dip zinc-coated (thickness approx. 20 m) steel sheet (thickness 1.5 mm) with
polyester thermosetting powder coating (thickness approx. 80 m) on visible surfaces
except back panel. Colour: RAL 7035 (light beige, semigloss).
Busbars Tin- or silver-plated copper
Internal cooling circuit piping Aluminium, acid-fast stainless steel, PA pipes
Fire safety of materials
(IEC 60332-1)
Insulating materials and non-metallic items: Mostly self-extinctive
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.
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)
84
85
Dimensions and weight
Type Frame size Height1 Space
above
1)
Depth Width Weight
[mm] [mm] [mm] [mm] [kg]
U
N
= 400 V (Range 380415 V)
ACS800-207LC-0240-3 R8i 2003 400 644 1000 850
ACS800-207LC-0330-3 R8i 2003 400 644 1000 850
ACS800-207LC-0410-3 R8i 2003 400 644 1000 850
ACS800-207LC-0540-3 R8i 2003 400 644 1200 1150
ACS800-207LC-0820-3 2R8i 2003 400 644 1400 1500
ACS800-207LC-1070-3 2R8i 2003 400 644 1400 1500
ACS800-207LC-1580-3 3R8i 2003 400 644 2400 2350
ACS800-207LC-2090-3 4R8i 2003 400 644 2200 2450
ACS800-207LC-3100-3 6R8i 2003 400 644 3400 2700
U
N
= 500 V (Range 380500 V)
ACS800-207LC-0280-5 R8i 2003 400 644 1000 850
ACS800-207LC-0370-5 R8i 2003 400 644 1000 850
ACS800-207LC-0470-5 R8i 2003 400 644 1000 850
ACS800-207LC-0620-5 R8i 2003 400 644 1200 1150
ACS800-207LC-0940-5 2R8i 2003 400 644 1400 1500
ACS800-207LC-1220-5 2R8i 2003 400 644 1400 1500
ACS800-207LC-1810-5 3R8i 2003 400 644 2400 2350
ACS800-207LC-2390-5 4R8i 2003 400 644 2200 2450
ACS800-207LC-3550-5 6R8i 2003 400 644 3400 2700
U
N
= 690 V (Range 525690 V)
ACS800-207LC-0260-7 R8i 2003 400 644 1000 850
ACS800-207LC-0360-7 R8i 2003 400 644 1000 850
ACS800-207LC-0430-7 R8i 2003 400 644 1000 850
ACS800-207LC-0570-7 R8i 2003 400 644 1000 850
ACS800-207LC-0860-7 2R8i 2003 400 644 1400 1500
ACS800-207LC-1120-7 2R8i 2003 400 644 1400 1500
ACS800-207LC-1670-7 3R8i 2003 400 644 1700 1750
ACS800-207LC-2200-7 4R8i 2003 400 644 2200 2450
ACS800-207LC-3270-7 6R8i 2003 400 644 2800 2950
ACS800-207LC-4360-7 8R8i 2003 400 644 4200 3650
ACS800-207LC-4900-7 9R8i 2003 400 644 4300 4400
ACS800-207LC-5450-7 10R8i 2003 400 644 5000 5650
1) Free space above to allow opening of pressure relief vents (that open automatically upon arc fault)
Depth Depth excluding the door equipment (switches, handles, etc.).
Width Basic unit with main breaker or contactor cubicle (+F250, +F255). For information on the widths
including all options, see Cubicle widths and positions in the cabinet line-up on page 86.
Weight Weight of basic unit (no options) with an empty cooling circuit
86
Cubicle widths and positions in the cabinet line-up
Seen from front, the drive consists of the following units from left to right:
supply unit
inverter unit
brake unit (optional)
liquid-cooling unit (optional).
The data is divided accordingly in the multidrive manuals. This manual describes the
cubicle widths and positions in the IGBT supply unit.
Cubicle widths and positions in the IGBT supply unit
The table below shows the supply unit cubicle widths in millimetres and the position
(index) in the supply unit line-up. See the subsection Ratings on page 67 for the
supply modules and supply units used in each ACS800-207LC.
* Cubicle with the control electronics
Cubicle Supply
modules
Width Index
1R8i units 0540-3, 0620-5
ACU1 - 400/600 5
ICU1 - 600 45
ADU1 - 200 60
RFI1 - 300 65
LCL1 - 300 90
ISU1* 1R8i 300 95
1R8i all units except 0540-3, 0620-5 1)
ACU1 - 400/600 5
ICU1 - 400 55
RFI1 - 300 65
LCL1 - 300 90
ISU1* 1R8i 300 95
2R8i all 400V and 500V units
ACU1 - 400/600 5
ICU1 - 600 45
ADU1 - 200 60
LCL1 - 300 120
ISU1* 2R8i 500 125
2R8i all 690V units
ACU1 - 400/600 5
ICU1 - 600 45
ADU1 - 200 60
RFI1 - 300 65
LCL1 - 300 120
ISU1* 2R8i 500 125
ACU1 - 400/600 5
ICU1 - 600 45
ADU1 - 200 60
LCL1 - 300 70
ISU1* 1R8i 300 75
LCL2 - 300 80
ISU2 1R8i 300 85
LCL3 - 300 90
ISU3 1R8i 300 95
3R8i all 690V units
ACU1 - 400/600 5
ICU1 - 600 45
ADU1 - 200 60
LCL1 - 400 140
ISU1* 3R8i 700 145
4R8i all units
ACU1 - 400/600 5
ICU1 - 600 45
ADU1 - 200 60
LCL1 - 300 100
ISU1* 2R8i 500 105
LCL2 - 300 120
ISU2 2R8i 500 125
ACU1 - 400/600 5
LCL1 - 300 10
ISU1* 2R8i 500 15
ADU2 - 200 40
ICU1 - 1000 50
ADU1 - 200 60
LCL2 - 300 100
ISU2 2R8i 500 105
LCL3 - 300 120
ISU3 2R8i 500 125
6R8i all 690V units
ACU1 - 400/600 5
ICU1 - 600 45
ADU1 - 200 60
LCL1 - 400 130
ISU1* 3R8i 700 135
LCL2 - 400 140
ISU2 3R8i 700 145
Cubicle Supply
modules
Width Index
8R8i 690V only
ACU1 - 400/600 5
LCL1 - 300 10
ISU1* 2R8i 500 15
LCL2 - 300 20
ISU2 2R8i 500 25
ADU2 - 200 40
ICU1 - 1000 50
ADU1 - 200 60
LCL3 - 300 100
ISU3 2R8i 500 105
LCL4 - 300 120
ISU4 2R8i 500 125
9R8i 690V only
ACU1 - 400/600 5
LCL1 - 400 30
ISU1* 3R8i 700 35
ADU2 - 200 40
ICU1 - 1000 50
ADU1 - 200 60
LCL2 - 400 130
ISU2 3R8i 700 135
LCL3 - 400 140
ISU3 3R8i 700 145
10R8i 690V only
ACU1 - 400/600 5
LCL1 - 300 10
ISU1* 2R8i 500 15
LCL2 - 300 20
ISU2 2R8i 500 25
ADU2 - 200 40
ICU1 - 1000 50
ADU1 - 200 60
LCL3 - 300 100
ISU3 2R8i 500 105
LCL4 - 300 110
ISU4 2R8i 500 115
LCL5 - 300 120
ISU5 2R8i 500 125
00503842.xls A-8
Cubicle Supply
modules
Width Index
87
Abbreviations and option codes The table below describes the abbreviations of the cubicle names and module
names. The table also shows the option codes which indicate the use of certain optional cubicle.
Index Each cubicle has a predesigned position in the supply unit line-up which is indicated by an index. The lower
the index, the further left the cubicle is positioned in the unit.
Abbr. Description Option code
ACU Auxiliary control cubicle. Included with option +Z010 or +Z020
ADU Adapter cubicle. Included with top cable entry option. +H351
ICU Incoming cubicle. Included with main breaker or contactor option. +F250 or +F255
ISU Supply module cubicle -
LCL LCL filter cubicle -
R8i IGBT supply module, frame size R8i -
RFI1 RFI filter cubicle. Included with RFI filter option. +E202
88
89
This chapter contains specifications of the inputs and outputs of the RMIO board.
To which board type and revisions this chapter applies
This chapter applies to RMIO-01 board from revision J onwards and RMIO-02 board
from revision H onwards.
RMIO board specifications
Analogue inputs
With Standard Application Program two programmable differential current inputs (0 mA
/ 4 mA... 20 mA, R
in
= 100 ohm) and one programmable differential voltage input (-10 V
/ 0 V / 2 V... +10 V, R
in
= 200 kohm).
The analogue inputs are galvanically isolated as a group.
Isolation test voltage 500 V AC, 1 min.
Max. common mode voltage
between the channels
15 V DC
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 V DC, 0, -10 V DC 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 V DC 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, R
L
< 700 ohm
Resolution 0.1% (10 bit)
Inaccuracy 1% (Full Scale Range) at 25 C (77F). Temperature coefficient: 200 ppm/C
( 111 ppm/F) max.
90
Digital inputs
With Standard Application Program six programmable digital inputs (common ground:
24 V DC, -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 V DC): short-circuit proof. An external 24 V DC
supply can be used instead of the internal supply.
Isolation test voltage 500 V AC, 1 min.
Logical thresholds < 8 V DC 0, > 12 V DC 1
Input current DI1 to DI 5: 10 mA, DI6: 5 mA
Filtering time constant 1 ms
Relay outputs
Three programmable relay outputs
Switching capacity 8 A at 24 V DC or 250 V AC, 0.4 A at 120 V DC
Minimum continuous current 5 mA rms at 24 V DC
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 V DC power input
Voltage 24 V DC 10%
Typical current consumption
(without optional modules)
250 mA
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 the installation site is below 2000 m (6562 ft). Above 2000 m (6562 ft), consult an ABB representative.
91
Isolation and grounding diagram
X20
1 VREF-
2 AGND
X21
1 VREF+
2 AGND
3 AI1+
4 AI1-
5 AI2+
6 AI2-
7 AI3+
8 AI3-
9 AO1+
10 AO1-
11 AO2+
12 AO2-
X22
1 DI1
2 DI2
3 DI3
4 DI4
9 DGND1
5 DI5
6 DI6
7 +24VD
8 +24VD
11 DIIL
10 DGND2
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
Common mode
voltage between
channels 15 V
J1
(Test voltage: 500 V AC)
or
Jumper J1 settings:
All digital inputs share a common
ground. This is the default setting.
Grounds of input groups
DI1DI4 and DI5/DI6/DIIL
are separate (isolation
voltage 50 V).
Ground
(Test voltage:
4 kV AC)
92
93
This chapter contains a circuit diagram set of cabinet-installed IGBT supply unit
which is equipped with two R8i supply modules. The most commonly used line side
control devices are included: a main breaker, a three-position operating switch and a
reset button. The purpose of the diagrams is to illustrate the connection principles in
order to help in understanding the operation of the system.
WARNING! Never connect, test or measure anything in a drive based on the
information given in the diagrams below. Each multidrive delivery is unique, and the
actual wiring of the drive delivery does not correspond to these example diagrams.
Always refer to the delivery specific circuit diagrams for complete information of the
drive connections, terminal markings, etc.
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
3
A
F
E
6
8
8
2
2
0
9
2

R
E
V

A

/

E
N
E
F
F
E
C
T
I
V
E
:

3
0
.
0
3
.
2
0
0
7
ABB Oy
AC Drives
P.O. Box 184
FI-00381 HELSINKI
FINLAND
Telephone +358 10 22 11
Fax +358 10 22 22681
Internet www.abb.com
ABB Inc.
Automation Technologies
Drives & Motors
16250 West Glendale Drive
New Berlin, WI 53151
USA
Telephone 262 785-3200
800-HELP-365
Fax 262 780-5135
ABB Beijing Drive Systems Co. Ltd.
No. 1, Block D, A-10 Jiuxianqiao Beilu
Chaoyang District
Beijing, P.R. China, 100015
Telephone +86 10 5821 7788
Fax +86 10 5821 7618
Internet www.abb.com

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