Acs800 207lc Hw Manual Rev A

ACS800

Hardware ManualACS800-207LC 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 3AFE68822092ACS800 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 3AFE68835861ACS800 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 3AFE64616340Master/Follower Application Guide 3AFE64590430Pump Control Application Program Firmware Manual 3AFE68478952Extruder Control Program Supplement 3AFE64648543Centrifuge Control Program Supplement 3AFE64667246Traverse Control Program Supplement 3AFE64618334Crane Control Program Firmware Manual 3BSE11179etc.

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 delivery2) Included in the delivery with appropriate supply unit3) Included in the delivery with appropriate program or option device4) Included in the delivery with the optional liquid cooling unit

ACS800-207LCIGBT Supply UnitsHardware Manual

3AFE68822092 Rev AEN

EFFECTIVE: 30.03.2007

© 2007 ABB Oy. All Rights Reserved.

5

Table of contents

Table of contents

About this manual

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Common chapters for several products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Installation and commissioning flowchart of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Other documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

How the IGBT supply unit operates

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15AC voltage and current waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Hardware description

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Overview of a drive with an IGBT supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Composition of the supply unit cubicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Layout view � Auxiliary control cubicle (option +Z010 or +Z020) . . . . . . . . . . . . . . . . . . . . . . . . . . 18Layout view � Main contactor cubicle (option +F250) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Layout view � Main breaker cubicles (option +F255) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

600 mm wide cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191000 mm wide cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Layout view � Supply module and LCL filter cubicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Single-line diagram of a supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Overview of IGBT supply module R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Connections and use of the IO in the supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Connections to standard I/O terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Type designation labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Type code of cabinet-installed IGBT supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Basic code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Option codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Table of contents

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Type code of IGBT supply module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Basic code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Option codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Electrical installation

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Input cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Checking the compatibility with IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Power connections � unit with in-built main breaker or contactor (option +F255 or +F250) . . . . . 32

Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Power connections � unit without in-built main breaker or contactor (no option +F255 or +F250) 34Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Main breaker/contactor control connections � unit without in-built main breaker or contactor (no option +F255 or +F250) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Installation of optional modules and PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36PC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Installation of option modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Cabling of I/O and fieldbus modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Fibre optic links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Connections of the auxiliary voltage transformer (option +G344) . . . . . . . . . . . . . . . . . . . . . . . . . 38Connection of external power supply for the auxiliary circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Connection diagram, case 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Connection diagram, case 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Connection diagram, case 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Installation checklist

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Start-up and operation

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Operating instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Fault tracing

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47LEDs of the drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Table of contents

7

Maintenance

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Replacing and reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Capacitor replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Replacing the cooling fans in incoming cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Replacing the fan in 400 mm wide incoming cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Replacing the fan in 600 mm or 1000 mm wide incoming cubicle . . . . . . . . . . . . . . . . . . . . . . . 51

Replacing the cooling fans in supply module cubicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Installing the installation stand for supply module R8i replacement . . . . . . . . . . . . . . . . . . . . . . . . 53Replacing the supply module R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Installing the winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

The internal cooling circuit

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Internal cooling system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Connection to a cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Connection to an ACS800-1007LC cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Connection to a custom cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

General requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Coolant temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Filling up and bleeding the internal cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Draining the internal cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Adding inhibitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Temperature limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Pressure limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Water quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Freeze protection and corrosion inhibition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Glycol concentration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Technical data � ACS800-207LC

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Auxiliary circuit current consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Losses, coolant flow and quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Internal cooling circuit data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Input busbar and cable lead-through data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Table of contents

8

Units with built-in main breaker (option +F255) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Input power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Output power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Internal cooling circuit data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71Standards and markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71US patents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Technical data � ACS800-104LC modules

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Type equivalence table and frame sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Auxiliary circuit current consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76LCL filter types, data and use with supply modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Supply module capacitances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Losses, coolant flow and quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Internal cooling circuit data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80AC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80DC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Output connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82Input power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Tightening torques for power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83US patents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Dimensions and weights

Dimensions and weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Cubicle 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

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89To which board type and revisions this chapter applies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89RMIO board specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Analogue inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Constant voltage output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Table of contents

9

Auxiliary power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Analogue outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90Relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90DDCS fibre optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9024 V DC power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

IGBT supply unit example circuit diagrams

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Table of contents

10

Table of contents

11

About this manual

What this chapter containsThis chapter describes the intended audience and contents of the manual. It also contains an installation and commissioning flowchart and the ABB contact information.

CompatibilityThis manual is compatible with ACS800-207LC, the liquid-cooled and cabinet-installed IGBT supply units.

Intended audienceThis 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 productsSome chapters apply also to ACS800-104LC IGBT supply module or the complete multidrive. This is indicated in the introduction of the chapter.

ContentsThe 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 [3AFE68715423 (English)].

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 documentsUser 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

InquiriesAddress 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 inquiriesAddress 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 DefinitionAPBU 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

www.abb.com/drives

www.abb.com/drives

www.abb.com/drives

14

Product trainingFor 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 manualsYour 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.

About this manual

www.abb.com/drives

www.abb.com/drives

15


What this chapter containsThis 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 principleThe 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 fusesIGBT supply moduleAC fuses

DC outputAC input


16

AC voltage and current waveformsThe 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 (Lsupply line) to total line inductance (Lsupply line + LLCL filter).

Typical line current (iU) and voltage (uUV) 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

uUV

t [ms]

iU

I [A], U [V AC]

��

��

��

��

��

��

��

� � ��

THD

Cur

rent

[%]

Ordinal no. ofharmonic


17


What this chapter containsThis 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 (ACS800-104LC) if they are equipped with similar auxiliary devices.

Overview of a drive with an IGBT supply unitThe 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 cubiclesThe 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. Description1. 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 41c

0 1

1

1a


18

Layout view � Auxiliary control cubicle (option +Z010 or +Z020)

Layout view � Main contactor cubicle (option +F250)

No. Description1. 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. Description1. 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







6. Charging circuit switch

7. Main breaker

8. Earthing switch

9. Heat exchanger and fans

31

2

6

7

9

8

45






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 cubiclesFigure below is an example showing a unit with two parallel R8i modules.

No. Description1. 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 unitThe 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 R8iThe 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< LCL2×ACS800

RMIO

Control circuitry

board

-104LC

~

=

APBUboard

~

=

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

0START

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 boardsThe 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

NRED13

X4X2

2

AGDRX10 X2

AGDRX10 X2

AGDR

AINT

X10 X2 X1

X7

APOWX1X2X8

Phase current measurements (3)

IGBT control pulses

V2

RMIO

RDCU

V68V1V57

X2X34

IGBT supply module2

V5

24 V

1)n

X2X3


23

Control interfacesThe 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 powerTo 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

0St

1 ResetEm. stop


24

Connections and use of the IO in the supply unitThe 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 terminalsX201 VREF- Reference voltage -10 V DC, 1 kohm < RL < 10

kohm2 AGNDX211 VREF+ Reference voltage 10 V DC, 1 kohm < RL < 10

kohm2 AGND3 AI1+ Not in use. 1) 0(2)�10 V, Rin > 200 kohm

4 AI1-5 AI2+ Not in use. 1) 0(4)�20 mA, Rin = 100 ohm

6 AI2-7 AI3+ Not in use. 1) 0(4)�20 mA, Rin = 100 ohm

8 AI3-9 AO1+ Not in use. 1) 0(4)�20 mA, RL < 700 ohm

10 AO1-11 AO2+ Not in use. 1) 0(4)�20 mA, RL < 700 ohm

12 AO2-X221 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 +24V9 DGND1 Digital ground

10 DGND2 Digital ground

11 DIIL Not in use 1)

X231 +24V Auxiliary voltage output, non-isolated, 24 V DC

250 mA2 GNDX251 RO1 Charging contactor control: Open (0) /

close (1)2 RO13 RO1X261 RO2 LCU control: Off (0) / on (1)

2 RO23 RO2X271 RO3 Main breaker/contactor control: open (0)

/ close (1)2 RO33 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 mm2 (22 to 12 AWG) Tightening torque: 0.2 to 0.4 N·m (0.2 to 0.3 lb.ft)

START10

3

4

1

2

Control circuitry

Main breaker/contactor

Charging contactor

Operating switch


26

Type designation labelsThe 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 unit�s 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

12

4 3

Type designation label of ACS800-104LC supply and inverter module

12

36

5


27

Type code of cabinet-installed IGBT supply unitType 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 codesThis 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

1�6 Product series ACS800 Industrial drives

8�10 Construction 207 IGBT Supply Unit

11, 12 Cooling LC Liquid-cooling

14�17 Size 240�5450 Size of the unit

19 Voltage rating 3 380�415 V

5 380�500 V

7 380�690 V

Class Code DescriptionSupply frequency A012 Supply frequency 50 Hz *

A013 Supply frequency 60 HzDegree of protection B054 IP42, UL type 1, NEMA 1 *

B055 IP54, UL type 12, NEMA12Cabinet construction 0C121 Industrial construction *

C121 Marine constructionStandards 0C129 IEC standards *

C134 CSA-approved componentsC129 UL-approved components

Cooling unit type 0C138 No cooling unit *C138 Line-up connected cooling unitC139 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 contactorF254 Switch fuse

Breaker option 0F255 No F255 *F255 Circuit breaker

Earthing switch 0F259 No F259 *F259 Earthing switch

Cabinet options G300 Cabinet heaterControl voltage for relays and fans G320 230 V AC *

G304 115 V ACTerminals for external control voltage 0G307 No G307 *

G307 Terminals for external control voltageDC bus material G315 Tin plated copperWiring materials 0G330 Standard wire material *

G330 Halogen free wiringSupply conductor type G316 Cable supply conductors *

G317 Busbar supply conductorsArc monitoring 0G336 No G336 (no arc monitoring) *

G336 Arc monitoringG337 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 doorMeters 0G334 No G334 (no meters on door) *

G334 V-meter with selector switchG335 A-meter in one phase3G335 A-meter in three phasesG333 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 400Z020 ACU width 600

Drive window option Z040 Drive window selected (plastic + silica)DriveBus branching unit 0Z050 No Z050 *

Z050 NDBU-44Emergency stop acknowledgment Z150 Via RMIO

Z160 Via AC800Emergency stop location Z170 Standard

Z180 MasterZ190 Follower

CDP-panels 0J400 No J400J400 Control panel CDP 312R *

LMD-panels 0J401 No J401 *J401 Drive monitoring display

Panels 0K450 No K450 (no panels) *J410 Drive control panel connection kitK450 Panel Bus selected

Class Code Description


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 3L509 DDCS communication 2 *L508 DDCS communication 1

Special options G343 Corrosion coupon in ACUP902 Customised (described in technical appendix)P904 Extended warrantyP913 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 0Q952 Emergency stop, stop category 1

Earth fault monitoring 0Q953 No Q953 (no earth fault monitoring device) *Q953 Earth fault monitoring, earthed mains TNQ954 Earth fault monitoring, unearthed mains IT

Safety category 0Q962 No Q962 (no safety category selected) *Q962 Safety category 1Q961 Safety category 3

Documentation languages R700 English *R701 GermanR702 ItalianR703 DutchR704 DanishR705 SwedishR706 FinnishR707 FrenchR708 SpanishR709 Portuguese (spoken in Portugal)R710 Portuguese (spoken in Brazil)R711 RussianR712 Chinese

Power rating of control voltage transformer

0Z260 No Z260 (no control voltage transformer) *Z260 2500 VAZ280 4000 VAZ290 6300 VAZ300 9000 VAZ310 12000 VA

External control voltage supply / UPS size

Z225 Max. current 16 AZ230 Max. current 25 AZ240 Max. current 40 AZ250 Max. current 63 A

Motor options Z1220 Supply for motor fanZ1230 Supply for motor heater

Class Code Description


30

Type code of IGBT supply moduleEach 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

1�6 Product series ACS800 Industrial drives

8�10 Construction 104 IGBT supply module or inverter module

11, 12 Cooling LC Liquid-cooling

14�17 Size 310�6620 Size of the module

19 Voltage rating 3 380�415 V

5 380�500 V

7 380�690 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 n×R8i only.

G Supply voltage for fan

G304 115 V AC


31


What this chapter containsThis 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 (ACS800-104LC) if they are equipped with similar auxiliary devices.

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 Installation [3AFE68715423 (English)].

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

ohmM


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 [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 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 procedure1. 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 N·m [55 lb.ft].

� Connect the phase conductors to the input power terminals. Tightening torque = 70 N·m [55 lb.ft].

4. Replace the protecting shroud and close the door.

Detail of cable lead-throughTo suppress interference, use shielded three-phase cables and ground the shields 360° at the lead-through.

23

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~

=3 54 6

Incomingcubicle

Supply module and LCL filter cubicles


35

Connection procedure1. 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 N·m [55 lb.ft].

� Connect the phase conductors to the input power terminals. Tightening torque = 70 N·m [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-throughTo suppress interference, use shielded three-phase cables and ground the shields 360° at the lead-through.

23

Input busbars

Charging circuit main switch (Q2.1)


36

Control connections

GeneralAs 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 Multidrive and Multidrive Modules Safety Instructions [3AFE68715318 (English)]. Ignoring the instructions can cause physical injury or death, or damage to the 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 linksDDCS 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 User�s 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

2 3 41

Keep unshielded portion asshort 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

232425

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

232425

26

0 (Ground)

115 V AC

230 V AC

2

3

4

5

6

Transformer for 380�500 V AC input voltage

Transformer for 525�690 V AC input voltage


39

Connection of external power supply for the auxiliary circuitsThere 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.

L1L2L3

PE

>

L N

NL

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

X111 2

PE

PE5


40



>

Power supply for control 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+G307 Terminals for external control

voltage (UPS)= No

X11

F19F11

1 2 PE5 3 4 PE6

PE

>

Power supply for control circuitry

Power supply for fans

L NPE

>

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+G307 Terminals for external control

voltage (UPS)= Yes

F19F11

1 2 PE5X11

3 4 PE6


41


What this chapter containsThis chapter contains a list for checking the mechanical and electrical installation of the drive.

Installation checklistCheck 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 Multidrive and Multidrive Modules Safety Instructions [3AFE68715318 (English)]. Ignoring the instructions can cause physical injury or death, or damage to the 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


What this chapter containsThis 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-upAction 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 ruleEnsure 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 limitAs a rule of thumb, this should be set to the rated AC current of the supply unit.Peak current limitAs 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 V AC 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 User�s Manual [3AFE68621101 (English)].

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.

Action Additional information


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) × U1N = 1.41 × nominal rms voltage of the power lineNote: 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 [3AFE68315735 (English)].

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 User�s Manual [3AFE68621101 (English)].

Action Additional information


46

Operating instructionsThis 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 operator�s 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 [3AFE68315735 (English)].


47

Fault tracing

What this chapter containsThis 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

Fault tracing

49

Maintenance

What this chapter containsThis 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 intervalsIf 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 User�s Manual [3AFE68621101 (English)].

Replacing and reforming the capacitorsThe 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

ReformingReform (re-age) spare part capacitors once a year according to Capacitor Reforming Guide [3AFE64059629 (English)], available from your local ABB representative.

Capacitor replacementContact an ABB service representative.

Replacing the cooling fans in incoming cubicle

Replacing the fan in 400 mm wide incoming cubicleThere is 400 mm wide incoming cubicle in units with option +F250 (line contactor).

WARNING! Read and follow the instructions 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.

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 Multidrive and Multidrive Modules Safety Instructions [3AFE68715318 (English)]. Ignoring the instructions can cause physical injury or death, or damage to the equipment.


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

35

22

Maintenance

52

Replacing the cooling fans in supply module cubicle



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 replacement1. 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 N·m [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



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

aa

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 N·m.

� Clean all contact surfaces of the quick connector and apply a layer of suitable joint compound (e.g. Isoflex® Topas NB 52 from Klüber Lubrication) onto them.

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

1212

12

12

1212

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 N·m. Ensure that the studs are in frame holes when tightening the screws.

Maintenance

59


GeneralThe 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 diagramThe 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 CoolantOUT

CoolantIN

A/L = Air to liquid heat exchanger

A/L A/L A/LA/LA/L A/L


60

Connection to a cooling unit

Connection to an ACS800-1007LC cooling unitRefer to the ACS800-1007LC Cooling Units User�s Manual [3AFE68621101 (English)].

Connection to a custom cooling unitGeneral 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 circuitInternal circuit


61

Filling up and bleeding the internal cooling circuitBoth 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 100�150 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 circuitThe 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 inhibitorAdd 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 limitsAmbient 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 (φ) and the ambient temperature (Tair).

Maximum coolant inlet temperature for ACS800 liquid-cooled driveDrive 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.

Tair(°C)

Min. Tcoolant (°C)φ = 95% φ = 80% φ = 65% φ = 50% φ = 40%

5 4.3 1.9 -0.9 -4.5 -7.410 9.2 6.7 3.7 -0.1 -3.015 14.2 11.5 8.4 4.6 1.520 19.2 16.5 13.2 9.4 6.025 24.1 21.4 17.9 13.8 10.530 29.1 26.2 22.7 18.4 15.035 34.1 31.1 27.4 23.0 19.440 39.0 35.9 32.2 27.6 23.845 44.0 40.8 36.8 32.1 28.250 49.0 45.6 41.6 36.7 32.855 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 limitsBase pressure: 100�150 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 inhibitionA 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 waterThe 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/lSulphate < 200 mg/lTotal dissolved solids no deposits are allowed at the tempera-

ture of +57 °CMaximum particle size < 1 mmTotal hardness as CaCO3 < 250 mg/lConductivity < 400 µS/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.

MaterialsMaterials 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 TeflonNote: 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 0-20T (°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


What this chapter containsThis chapter contains the technical data for the cabinet-installed IGBT supply units ACS800-207LC.

RatingsRatings with 50 Hz and 60 Hz supplies.

IGBT Supply UnitType

Basic module ACS800-104LC�

Framesize

No overload use Light overload use Heavy-duty useIcontmax Icontmax Imax SN Pcontmax In PN Ihd Phd

A AC A DC A DC kVA kW DC A DC kW A DC kWUN=400 V (Range 380�415 V)ACS800-207LC-0240-3 -0240-3 R8i 341 413 471 245 243 397 233 309 181ACS800-207LC-0330-3 -0330-3 R8i 454 550 627 326 323 528 310 411 241ACS800-207LC-0410-3 -0410-3 R8i 567 687 784 408 403 660 387 514 302ACS800-207LC-0540-3 -0540-3 R8i 756 917 1046 543 538 880 516 686 402ACS800-207LC-0820-3 -0470-3+E205 2×R8i 1134 1375 1568 815 807 1320 775 1028 604ACS800-207LC-1070-3 -0620-3+E205 2×R8i 1482 1797 2049 1065 1054 1725 1012 1344 789ACS800-207LC-1580-3 -0620-3+E205 3×R8i 2200 2667 3042 1581 1565 2560 1503 1995 1171ACS800-207LC-2090-3 -0620-3+E205 4×R8i 2903 3520 4015 2087 2066 3379 1983 2633 1545ACS800-207LC-3100-3 -0620-3+E205 6×R8i 4309 5225 5960 3097 3066 5016 2944 3908 2294UN=500 V (Range 380�500 V)ACS800-207LC-0280-5 -0280-5 R8i 324 393 475 281 278 377 267 294 208ACS800-207LC-0370-5 -0370-5 R8i 432 524 633 374 370 503 356 392 277ACS800-207LC-0470-5 -0470-5 R8i 540 655 792 468 463 629 444 490 346ACS800-207LC-0620-5 -0620-5 R8i 720 873 1056 624 617 838 593 653 462ACS800-207LC-0940-5 -0550-5+E205 2×R8i 1080 1309 1584 935 926 1257 889 980 693ACS800-207LC-1220-5 -0730-5+E205 2×R8i 1411 1711 2069 1222 1210 1643 1162 1280 905ACS800-207LC-1810-5 -0730-5+E205 3×R8i 2095 2540 3072 1814 1796 2439 1724 1900 1344ACS800-207LC-2390-5 -0730-5+E205 4×R8i 2765 3352 4054 2394 2370 3218 2276 2508 1773ACS800-207LC-3550-5 -0730-5+E205 6×R8i 4104 4976 6017 3554 3519 4777 3378 3722 2632UN=690 V (Range 525�690 V)ACS800-207LC-0260-7 -0260-7 R8i 216 262 327 258 256 251 245 196 191ACS800-207LC-0360-7 -0360-7 R8i 300 364 453 359 355 349 341 272 266ACS800-207LC-0430-7 -0430-7 R8i 360 436 544 430 426 419 409 327 319ACS800-207LC-0570-7 -0570-7 R8i 480 582 726 574 568 559 545 435 425ACS800-207LC-0860-7 -0550-7+E205 2×R8i 720 873 1088 860 852 838 818 653 637ACS800-207LC-1120-7 -0700-7+E205 2×R8i 941 1141 1422 1124 1113 1095 1069 853 833ACS800-207LC-1670-7 -0700-7+E205 3×R8i 1397 1694 2111 1669 1653 1626 1587 1267 1236ACS800-207LC-2200-7 -0700-7+E205 4×R8i 1843 2235 2786 2203 2181 2145 2094 1672 1631ACS800-207LC-3270-7 -0700-7+E205 6×R8i 2736 3317 4136 3270 3237 3185 3108 2481 2421ACS800-207LC-4360-7 -0700-7+E205 8×R8i 3648 4423 5514 4360 4316 4246 4144 3309 3228ACS800-207LC-4900-7 -0700-7+E205 9×R8i 4104 4976 6204 4905 4856 4777 4661 3722 3632ACS800-207LC-5450-7 -0700-7+E205 10×R8i 4560 5529 6893 5450 5395 5308 5179 4136 4036

00430970.xls C-20


68

Symbols

DeratingThe 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 × I2N or 0.95 × Icont.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)Icont.max Continuous RMS input (AC) and output (DC) current. No overloadability at 40 °C.Imax Maximum output current (DC). Allowable for 10 seconds at start, otherwise as long as allowed by drive

temperature.SN Apparent powerPcont.max Active powerRatings for light-overload use (10% overloadability)I2N Continuous rms current. 10% overload is allowed for 1 minute every 5 minutes.PN Active power, light overload useRatings for heavy-duty use (50% overloadability)I2hd Continuous rms current. 50% overload is allowed for 1 minute every 5 minutes.Phd Active power, heavy-duty use

%°C


69

Auxiliary circuit current consumptionThe 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 quantitySee chapter Technical data � ACS800-104LC modules.

Internal cooling circuit dataSee chapter The internal cooling circuit.

FusesSee chapter Technical data � ACS800-104LC modules.

Device/load Current consumption [A]1~230 V / 50 Hz

Supply1~230 V / 60 Hz


Supply 1)Note

IGBT Supply Unit and options24 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 (Y11.1�Y14.1) 0.4 0.5 0.7 5)

Fan in auxiliary control cubicle 0.4 0.5 0.7 4)

Inverter unit and options24 V DC power supply (U10) for boards and relays 1.3 1.3 2.5 -

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 unit24 V DC power supply, and control relays See ACS800-1007LC User�s Manual

[3AFE68621101 (English)].

Notes:1) Only with option +G304 (115 V AC 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 dataThe 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 connectionSee chapter Technical data � ACS800-104LC modules.

Output power connectionSee chapter Technical data � ACS800-104LC modules.

Degree of protectionIP42; IP54

Supply modules No. of busbars Screw size Tightening

torqueCable lead-throughs

400V / 500V / 690V

1×R8i 6 / 6 / 6 M12 (½�) 70 N·m (50 lb.ft) 18 × Ø60 mm

2×R8i 6 / 6 / 6 M12 (½�) 70 N·m (50 lb.ft) 18 × Ø60 mm

3×R8i 9 / 9 / 6 M12 (½") 70 N·m (50 lb.ft) 18 × Ø60 mm

4×R8i 9 / 9 / 6 M12 (½�) 70 N·m (50 lb.ft) 18 × Ø60 mm

6×R8i 9 / 9 / 9 M12 (½�) 70 N·m (50 lb.ft) 18 × Ø60 mm

1) Dimensions of input terminal in 600 mm breaker cubicle

2) Dimensions of input busbar in 1000 mm breaker cubicle


71

Ambient conditions

MaterialsSee page 83.


Standards and markingsSee 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

Storagein the protective package

Transportationin 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 3C2Solid particles: Class 3S2

Boards with coating: Chemical gases: Class 1C2Solid particles: Class 1S3

Boards with coating: Chemical gases: Class 2C2Solid particles: Class 2S2

Atmospheric pressure 70 to 106 kPa0.7 to 1.05 atmospheres

70 to 106 kPa0.7 to 1.05 atmospheres

60 to 106 kPa0.6 to 1.05 atmospheres

Vibration Marine requirements±1 mm (peak value, 2�13.2 Hz)0.7g (13.2 - 100 Hz)Max. amplification 10IEC 60068-2-60,075 mm (0�58 Hz) 10 m/s2 (58�150 Hz) Max. amplification 10

1M2, IEC 60721-3-11.5 mm (2�9 Hz)5 m/s2 (9�200 Hz)

2M2, IEC 60721-3-23,5 mm (2�9 Hz)10 m/s2 (9�200 Hz) Random 10-200 Hz, acceleration spectral density 1 m2/s3

Shock (IEC 60068-2-29) Not allowed Max. 100 m/s2 (330 ft./s2), 11 ms

Max. 100 m/s2 (330 ft./s2), 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 patentsSee ACS800 Liquid-cooled Multidrive and ACS800 Multidrive Modules Planning the Electrical Installation [3AFE68715423 (English)].


73


What this chapter containsThis chapter contains the technical data for IGBT supply modules ACS800-104LC.

RatingsSupply moduletype

No overload use Light overload use Heavy-duty useIcontmaxAC IcontmaxDC Imax SN Pcontmax In PN Ihd Phd

A (AC) A (DC) A (DC) kVA kW (DC) A (DC) kW A (DC) kWUN = 400 V (380�415 V)ACS800-104LC-0310-3+E205 341 413 471 245 243 397 233 309 181ACS800-104LC-0390-3+E205 454 550 627 326 323 528 310 411 241ACS800-104LC-0470-3+E205 567 687 784 408 403 660 387 514 302ACS800-104LC-0620-3+E205 756 917 1046 543 538 880 516 686 402ACS800-104LC-0920-3+E205 1134 1375 1568 815 807 1320 775 1028 604ACS800-104LC-1210-3+E205 1482 1797 2049 1065 1054 1725 1012 1344 789ACS800-104LC-1790-3+E205 2200 2667 3042 1581 1565 2560 1503 1995 1171ACS800-104LC-2370-3+E205 2903 3520 4015 2087 2066 3379 1983 2633 1545ACS800-104LC-3510-3+E205 4309 5225 5960 3097 3066 5016 2944 3908 2294UN = 500 V (380�500 V)ACS800-104LC-0330-5+E205 324 393 475 281 278 377 267 294 208ACS800-104LC-0470-5+E205 432 524 633 374 370 503 356 392 277ACS800-104LC-0550-5+E205 540 655 792 468 463 629 444 490 346ACS800-104LC-0730-5+E205 720 873 1056 624 617 838 593 653 462ACS800-104LC-1070-5+E205 1080 1309 1584 935 926 1257 889 980 693ACS800-104LC-1430-5+E205 1411 1711 2069 1222 1210 1643 1162 1280 905ACS800-104LC-2120-5+E205 2095 2540 3072 1814 1796 2439 1724 1900 1344ACS800-104LC-2790-5+E205 2765 3352 4054 2394 2370 3218 2276 2508 1773ACS800-104LC-4150-5+E205 4104 4976 6017 3554 3519 4777 3378 3722 2632UN = 690 V (525�690 V)ACS800-104LC-0310-7+E205 216 262 327 258 256 251 245 196 191ACS800-104LC-0480-7+E205 300 364 453 359 355 349 341 272 266ACS800-104LC-0550-7+E205 360 436 544 430 426 419 409 327 319ACS800-104LC-0700-7+E205 480 582 726 574 568 559 545 435 425ACS800-104LC-1070-7+E205 720 873 1088 860 852 838 818 653 637ACS800-104LC-1370-7+E205 941 1141 1422 1124 1113 1095 1069 853 833ACS800-104LC-2030-7+E205 1397 1694 2111 1669 1653 1626 1587 1267 1236ACS800-104LC-2680-7+E205 1843 2235 2786 2203 2181 2145 2094 1672 1631ACS800-104LC-3970-7+E205 2736 3317 4136 3270 3237 3185 3108 2481 2421ACS800-104LC-5300-7+E205 3648 4423 5514 4360 4316 4246 4144 3309 3228ACS800-104LC-5960-7+E205 4104 4976 6204 4905 4856 4777 4661 3722 3632ACS800-104LC-6620-7+E205 4560 5529 6893 5450 5395 5308 5179 4136 4036

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74

Symbols

DeratingThe 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 × I2N or 0.95 × Icont.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 useIcont.max Continuous RMS input (AC) and output (DC) currents. No overloadability at 40 °C.Imax Maximum output current. Allowable for 10 seconds at start, otherwise as long as allowed by drive

temperature.SN Nominal apparent powerPcont.max Active power (output power)Light-overload use (10% overloadability)In Continuous rms current. 10% overload is allowed for 1 minute every 5 minutes.PN Active power (output power)Typical ratings for heavy-duty use (50% overloadability)Ihd Continuous rms current. 50% overload is allowed for 1 minute every 5 minutes.Phd Active power (output power)

%°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 size1)

UN = 400 V (380�415 V)ACS800-104LC-0310-3+E205 ACS800-207LC-0240-3 - R8iACS800-104LC-0390-3+E205 ACS800-207LC-0330-3 - R8iACS800-104LC-0470-3+E205 ACS800-207LC-0410-3 - R8iACS800-104LC-0620-3+E205 ACS800-207LC-0540-3 - R8iACS800-104LC-0920-3+E205 ACS800-207LC-0820-3 ACS800-104LC-0470-3+E205 2×R8iACS800-104LC-1210-3+E205 ACS800-207LC-1070-3 ACS800-104LC-0620-3+E205 2×R8iACS800-104LC-1790-3+E205 ACS800-207LC-1580-3 ACS800-104LC-0620-3+E205 3×R8iACS800-104LC-2370-3+E205 ACS800-207LC-2090-3 ACS800-104LC-0620-3+E205 4×R8iACS800-104LC-3510-3+E205 ACS800-207LC-3100-3 ACS800-104LC-0620-3+E205 6×R8iUN = 500 V (380�500 V)ACS800-104LC-0330-5+E205 ACS800-207LC-0280-5 - R8iACS800-104LC-0470-5+E205 ACS800-207LC-0370-5 - R8iACS800-104LC-0550-5+E205 ACS800-207LC-0470-5 - R8iACS800-104LC-0730-5+E205 ACS800-207LC-0620-5 - R8iACS800-104LC-1070-5+E205 ACS800-207LC-0940-5 ACS800-104LC-0550-5+E205 2×R8iACS800-104LC-1430-5+E205 ACS800-207LC-1220-5 ACS800-104LC-0730-5+E205 2×R8iACS800-104LC-2120-5+E205 ACS800-207LC-1810-5 ACS800-104LC-0730-5+E205 3×R8iACS800-104LC-2790-5+E205 ACS800-207LC-2390-5 ACS800-104LC-0730-5+E205 4×R8iACS800-104LC-4150-5+E205 ACS800-207LC-3550-5 ACS800-104LC-0730-5+E205 6×R8iUN = 690 V (525�690 V)ACS800-104LC-0310-7+E205 ACS800-207LC-0260-7 - R8iACS800-104LC-0480-7+E205 ACS800-207LC-0360-7 - R8iACS800-104LC-0550-7+E205 ACS800-207LC-0430-7 - R8iACS800-104LC-0700-7+E205 ACS800-207LC-0570-7 - R8iACS800-104LC-1070-7+E205 ACS800-207LC-0860-7 ACS800-104LC-0550-7+E205 2×R8iACS800-104LC-1370-7+E205 ACS800-207LC-1120-7 ACS800-104LC-0700-7+E205 2×R8iACS800-104LC-2030-7+E205 ACS800-207LC-1670-7 ACS800-104LC-0700-7+E205 3×R8iACS800-104LC-2680-7+E205 ACS800-207LC-2200-7 ACS800-104LC-0700-7+E205 4×R8iACS800-104LC-3970-7+E205 ACS800-207LC-3270-7 ACS800-104LC-0700-7+E205 6×R8iACS800-104LC-5300-7+E205 ACS800-207LC-4360-7 ACS800-104LC-0700-7+E205 8×R8iACS800-104LC-5960-7+E205 ACS800-207LC-4900-7 ACS800-104LC-0700-7+E205 9×R8iACS800-104LC-6620-7+E205 ACS800-207LC-5450-7 ACS800-104LC-0700-7+E205 10×R8i

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76

Auxiliary circuit current consumptionThe 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)Note

IGBT supply unit and options24 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.) 3)

Inverter unit and options24 V DC power supply (U10) for boards and relays 1.3 1.3 2.5 -

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 unit24 V DC power supply, and control relays See ACS800-1007LC User�s Manual

[3AFE68621101 (English)].

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 modulesSupply moduletype

LCL filtertype

L1 L2 CInd. Weight loss Ind. Weight loss Cap. Weight loss

[microH] [kg] [kW] [microH] [kg] [kW] [microF] [kg] [kW]UN = 400 V (380�415 V) 0.1ACS800-104LC-0310-3+E205 ALCL-12LC-5 108 120 1.0 162 121 1.7 63 4.7 0.3ACS800-104LC-0390-3+E205 ALCL-13LC-5 81 125 1.1 122 125 1.7 83 5.6 0.3ACS800-104LC-0470-3+E205 ALCL-14LC-5 65 135 1.1 97 131 2.0 104 6.6 0.3ACS800-104LC-0620-3+E205 ALCL-15LC-5 49 130 1.3 73 157 2.4 139 9.8 0.4ACS800-104LC-0920-3+E205 ALCL-24LC-5 32 140 2.1 49 177 3.0 209 13.9 0.5ACS800-104LC-1210-3+E205 ALCL-25LC-5 25 140 3.8 45 225 3.4 273 19.4 0.7ACS800-104LC-1790-3+E205 3×ALCL-15LC-5 16 390 3.9 24 471 7.1 417 29.4 1.1ACS800-104LC-2370-3+E205 2×ALCL-25LC-5 13 280 7.6 23 450 6.8 546 38.8 1.4ACS800-104LC-3510-3+E205 3×ALCL-25LC-5 8 420 11.4 15 675 10.2 819 58.2 2.2UN = 500 V (380�500 V)ACS800-104LC-0330-5+E205 ALCL-12LC-5 108 120 1.0 162 121 1.7 63 4.7 0.3ACS800-104LC-0470-5+E205 ALCL-13LC-5 81 125 1.1 122 125 1.7 83 5.6 0.3ACS800-104LC-0550-5+E205 ALCL-14LC-5 65 135 1.1 97 131 2.0 104 6.6 0.3ACS800-104LC-0730-5+E205 ALCL-15LC-5 49 130 1.3 73 157 2.4 139 9.8 0.4ACS800-104LC-1070-5+E205 ALCL-24LC-5 32 140 2.1 49 177 3.0 209 13.9 0.5ACS800-104LC-1430-5+E205 ALCL-25LC-5 25 140 3.8 45 225 3.4 273 19.4 0.7ACS800-104LC-2120-5+E205 3×ALCL-15LC-5 16 390 3.9 24 471 7.1 417 29.4 1.1ACS800-104LC-2790-5+E205 2×ALCL-25LC-5 13 280 7.6 23 450 6.8 546 38.8 1.4ACS800-104LC-4150-5+E205 3×ALCL-25LC-5 8 420 11.4 15 675 10.2 819 58.2 2.2UN = 690 V (525�690 V)ACS800-104LC-0310-7+E205 ALCL-12LC-7 235 120 0.8 352 121 1.6 29 4.7 0.2ACS800-104LC-0480-7+E205 ALCL-13LC-7 169 120 1.1 254 120 1.7 40 6.2 0.3ACS800-104LC-0550-7+E205 ALCL-14LC-7 141 120 1.2 211 120 1.9 48 7.2 0.3ACS800-104LC-0700-7+E205 ALCL-15LC-7 106 140 1.3 159 130 2.1 64 9.8 0.3ACS800-104LC-1070-7+E205 ALCL-24LC-7 70 130 1.7 106 155 2.3 96 14.0 0.4ACS800-104LC-1370-7+E205 ALCL-25LC-7 54 130 2.4 97 185 3.7 125 16.2 0.6ACS800-104LC-2030-7+E205 ALCL-35LC-7 36 190 3.0 65 286 3.7 186 24.4 0.7ACS800-104LC-2680-7+E205 2×ALCL-25LC-7 27 260 4.8 49 370 7.4 250 32.4 1.2ACS800-104LC-3970-7+E205 2×ALCL-35LC-7 18 380 6 33 572 7.4 372 48.8 1.3ACS800-104LC-5300-7+E205 4×ALCL-25LC-7 14 520 9.6 24 740 14.8 500 64.8 2.4ACS800-104LC-5960-7+E205 3×ALCL-35LC-7 12 570 9 22 858 11.1 558 73.2 2.0ACS800-104LC-6620-7+E205 5×ALCL-25LC-7 11 650 12.0 19 925 18.5 625 81.0 3.1

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78

Supply module capacitancesSupply module type Capacitance

[mF]UN = 400 V (380�415 V)ACS800-104LC-0310-3+E205 10.3ACS800-104LC-0390-3+E205 14.4ACS800-104LC-0470-3+E205 16.4ACS800-104LC-0620-3+E205 20.5ACS800-104LC-0920-3+E205 32.8ACS800-104LC-1210-3+E205 41.0ACS800-104LC-1790-3+E205 61.5ACS800-104LC-2370-3+E205 82.0ACS800-104LC-3510-3+E205 123.0UN = 500 V (380�500 V)ACS800-104LC-0330-5+E205 10.3ACS800-104LC-0470-5+E205 14.4ACS800-104LC-0550-5+E205 16.4ACS800-104LC-0730-5+E205 20.5ACS800-104LC-1070-5+E205 32.8ACS800-104LC-1430-5+E205 41.0ACS800-104LC-2120-5+E205 61.5ACS800-104LC-2790-5+E205 82.0ACS800-104LC-4150-5+E205 123.0UN = 690 V (525�690 V)ACS800-104LC-0310-7+E205 6.1ACS800-104LC-0480-7+E205 7.7ACS800-104LC-0550-7+E205 9.2ACS800-104LC-0700-7+E205 10.7ACS800-104LC-1070-7+E205 18.4ACS800-104LC-1370-7+E205 21.5ACS800-104LC-2030-7+E205 32.2ACS800-104LC-2680-7+E205 42.9ACS800-104LC-3970-7+E205 64.4ACS800-104LC-5300-7+E205 85.9ACS800-104LC-5960-7+E205 96.6ACS800-104LC-6620-7+E205 107.3

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79

Losses, coolant flow and quantitySupply module type Losses Cooling media Efficiency

PlossISU PlossLCL Ploss tot Ploss_C Ploss_A Liquid qty.

Massflow Pressure loss1)

[kW] [kW] [kW] [kW] [kW] [l] [l/min] [kPa] [%]UN = 400 V (380�415 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%UN = 500 V (380�500 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%UN = 690 V (525�690 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

PlossISU Power loss of supply module(s)PlossLCL Power loss of supply LCL filterPloss tot Sum of PlossISU and PlossLCLPloss_C Power loss conducted to coolantPloss_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 recognized2) Not UL recognized (by the time of publishing this manual)3) UL recognized USA & Canada

Supply moduleACS800-104LC�


AC fuse informationType by Ferraz

ShawmutType byt Bussman

ABB factory code

In [A] Qty

UN=400 V (Range 380-415 V)-0310-3+E205 -0310-3+E205 6,6URD31TTF05501) 170M54111) 68731631 550 3-0390-3+E205 -0390-3+E205 6,6URD32TTF07001) 170M54131) 68752493 700 3-0470-3+E205 -0470-3+E205 6,6URD32TTF09001) 170M54151) 68752540 900 3-0620-3+E205 -0620-3+E205 6,6URD33TTF12501) 170M70591) 68704227 1250 3-0920-3+E205 -0470-3+E205 7,5URD44TQF20002) 170M70621) 68689589 2000 3-1210-3+E205 -0620-3+E205 7URD44TQF25003) 170M70631) 68752591 2500 3-1790-3+E205 -0620-3+E205 6,6URD33TTF12501) 170M70591) 68704227 1250 9-2370-3+E205 -0620-3+E205 7URD44TQF25003) 170M70631) 68752591 2500 6-3510-3+E205 -0620-3+E205 7URD44TQF25003) 170M70631) 68752591 2500 9UN=500 V (Range 380-500 V)-0380-5+E205 -0380-5+E205 6,6URD31TTF05501) 170M54111) 68731631 550 3-0470-5+E205 -0470-5+E205 6,6URD32TTF07001) 170M54131) 68752493 700 3-0550-5+E205 -0550-5+E205 6,6URD32TTF09001) 170M54151) 68752540 900 3-0730-5+E205 -0730-5+E205 6,6URD33TTF12501) 170M70591) 68704227 1250 3-1070-5+E205 -0550-5+E205 7,5URD44TQF20002) 170M70621) 68689589 2000 3-1430-5+E205 -0730-5+E205 7URD44TQF25003) 170M70631) 68752591 2500 3-2120-5+E205 -0730-5+E205 6,6URD33TTF12501) 170M70591) 68704227 1250 9-2790-5+E205 -0730-5+E205 7URD44TQF25003) 170M70631) 68752591 2500 6-4150-5+E205 -0730-5+E205 7URD44TQF25003) 170M70631) 68752591 2500 9UN=690 V (Range 525-690 V)-0310-7+E205 -0310-7+E205 6,6URD31TTF03501) 170M44111) 68731615 350 3-0480-7+E205 -0480-7+E205 6,6URD31TTF04501) 170M44131) 68731623 450 3-0550-7+E205 -0550-7+E205 6,6URD31TTF05501) 170M54111) 68731631 550 3-0700-7+E205 -0700-7+E205 6,6URD32TTF07001) 170M54131) 68752493 700 3-1070-7+E205 -0550-7+E205 6,6URD33TTF12501) 170M70591) 68704227 1250 3-1370-7+E205 -0700-7+E205 6,6URD33TTF14001) 170M70601) 68689571 1400 3-2030-7+E205 -0700-7+E205 7,5URD44TQF20002) 170M70621) 68689589 2000 3-2680-7+E205 -0700-7+E205 6,6URD33TTF14001) 170M70601) 68689571 1400 6-3970-7+E205 -0700-7+E205 7,5URD44TQF20002) 170M70621) 68689589 2000 6-5300-7+E205 -0700-7+E205 6,6URD33TTF14001) 170M70601) 68689571 1400 12-5960-7+E205 -0700-7+E205 7,5URD44TQF20002) 170M70621) 68689589 2000 9-6620-7+E205 -0700-7+E205 6,6URD33TTF14001) 170M70601) 68689571 1400 15

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81

DC fuses

1) UL recognized

Supply module ACS800-104LC�


DC fuse informationType by Ferraz

ShawmutType by

Bussman ABB factory

codeIn [A] Qty

UN = 400 V (380�415 V)-0310-3+E205 -0310-3+E205 6,9URD33TTF08001) 170M64121) 68731640 800 2-0390-3+E205 -390-3+E205 6,9URD33TTF11001) 170M64151) 68731658 1100 2-0470-3+E205 -0470-3+E205 6,9URD33TTF11001) 170M64151) 68731658 1100 2-0620-3+E205 -0620-3+E205 6,9URD73TTF16001) 170M64191) 68393108 1600 2-0920-3+E205 -0470-3+E205 6,9URD33TTF11001) 170M64151) 68731658 1100 4-1210-3+E205 -0620-3+E205 6,9URD73TTF16001) 170M64191) 68393108 1600 4-1790-3+E205 -0620-3+E205 6,9URD73TTF16001) 170M64191) 68393108 1600 6-2370-3+E205 -0620-3+E205 6,9URD73TTF16001) 170M64191) 68393108 1600 8-3510-3+E205 -0620-3+E205 6,9URD73TTF16001) 170M64191) 68393108 1600 12UN = 500 V (380�500 V)-0380-5+E205 -0380-5+E205 6,9URD33TTF08001) 170M64121) 68731640 800 2-0470-5+E205 -0470-5+E205 6,9URD33TTF11001) 170M64151) 68731658 1100 2-0550-5+E205 -0550-5+E205 6,9URD33TTF11001) 170M64151) 68731658 1100 2-0730-5+E205 -0730-5+E205 6,9URD73TTF16001) 170M64191) 68393108 1600 2-1070-5+E205 -0550-5+E205 6,9URD33TTF11001) 170M64151) 68731658 1100 4-1430-5+E205 -0730-5+E205 6,9URD73TTF16001) 170M64191) 68393108 1600 4-2120-5+E205 -0730-5+E205 6,9URD73TTF16001) 170M64191) 68393108 1600 6-2790-5+E205 -0730-5+E205 6,9URD73TTF16001) 170M64191) 68393108 1600 8-4150-5+E205 -0730-5+E205 6,9URD73TTF16001) 170M64191) 68393108 1600 12UN = 690 V (525�690 V)-0310-7+E205 -0310-7+E205 12,5URD73TTF04501) 170M65411) 68735971 450 2-0480-7+E205 -0480-7+E205 12,5URD73TTF07001) 170M65451) 68735980 700 2-0550-7+E205 -0550-7+E205 12,5URD73TTF08001) 170M65461) 68736005 800 2-0700-7+E205 -0700-7+E205 10URD73TTF11001) 170M6549 68736021 1100 2-1070-7+E205 -0550-7+E205 12,5URD73TTF08001) 170M65461) 68736005 800 4-1370-7+E205 -0700-7+E205 10URD73TTF11001) 170M6549 68736021 1100 4-2030-7+E205 -0700-7+E205 10URD73TTF11001) 170M6549 68736021 1100 6-2680-7+E205 -0700-7+E205 10URD73TTF11001) 170M6549 68736021 1100 8-3970-7+E205 -0700-7+E205 10URD73TTF11001) 170M6549 68736021 1100 12-5300-7+E205 -0700-7+E205 10URD73TTF11001) 170M6549 68736021 1100 16-5960-7+E205 -0700-7+E205 10URD73TTF11001) 170M6549 68736021 1100 18-6620-7+E205 -0700-7+E205 10URD73TTF11001) 170M6549 68736021 1100 20

00430970.XLS / C.32


82

Output connection

Degree of protectionIP00

Ambient conditionsSee page 71.

Input power connectionVoltage 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 units525/550/575/600/660/690 V AC 3-phase for 690 V AC 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 Icw , 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 Rsc > 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 U1max;Undervoltage: 60% of U1min (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 standardsSee ACS800 Liquid-cooled Multidrive and Multidrive Modules Planning the Electrical Installation [3AFE68715423 (English)].

MarkingsSee ACS800 Liquid-cooled Multidrive and Multidrive Modules Planning the Electrical Installation [3AFE68715423 (English)].

US patentsSee ACS800 Liquid-cooled Multidrive and Multidrive Modules Planning the Electrical Installation [3AFE68715423 (English)].

Cabinet Hot-dip zinc-coated (thickness approx. 20 µm) steel sheet (thickness 1.5 mm) with polyester thermosetting powder coating (thickness approx. 80 µm) on visible surfaces except back panel. Colour: RAL 7035 (light beige, semigloss).

Busbars Tin- or silver-plated copperInternal cooling circuit piping Aluminium, acid-fast stainless steel, PA pipesFire 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 TorqueM5 3.5 N·m (2.6 lbf.ft)M6 9 N·m (6.6 lbf.ft)M8 20 N·m (14.8 lbf.ft)M10 40 N·m (29.5 lbf.ft)M12 70 N·m (52 lbf.ft)M16 180 N·m (133 lbf.ft)


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Dimensions and weightType Frame size Height1 Space

above 1)Depth Width Weight

[mm] [mm] [mm] [mm] [kg]UN = 400 V (Range 380�415 V)ACS800-207LC-0240-3 R8i 2003 400 644 1000 850ACS800-207LC-0330-3 R8i 2003 400 644 1000 850ACS800-207LC-0410-3 R8i 2003 400 644 1000 850ACS800-207LC-0540-3 R8i 2003 400 644 1200 1150ACS800-207LC-0820-3 2×R8i 2003 400 644 1400 1500ACS800-207LC-1070-3 2×R8i 2003 400 644 1400 1500ACS800-207LC-1580-3 3×R8i 2003 400 644 2400 2350ACS800-207LC-2090-3 4×R8i 2003 400 644 2200 2450ACS800-207LC-3100-3 6×R8i 2003 400 644 3400 2700UN = 500 V (Range 380�500 V)ACS800-207LC-0280-5 R8i 2003 400 644 1000 850ACS800-207LC-0370-5 R8i 2003 400 644 1000 850ACS800-207LC-0470-5 R8i 2003 400 644 1000 850ACS800-207LC-0620-5 R8i 2003 400 644 1200 1150ACS800-207LC-0940-5 2×R8i 2003 400 644 1400 1500ACS800-207LC-1220-5 2×R8i 2003 400 644 1400 1500ACS800-207LC-1810-5 3×R8i 2003 400 644 2400 2350ACS800-207LC-2390-5 4×R8i 2003 400 644 2200 2450ACS800-207LC-3550-5 6×R8i 2003 400 644 3400 2700UN = 690 V (Range 525�690 V)ACS800-207LC-0260-7 R8i 2003 400 644 1000 850ACS800-207LC-0360-7 R8i 2003 400 644 1000 850ACS800-207LC-0430-7 R8i 2003 400 644 1000 850ACS800-207LC-0570-7 R8i 2003 400 644 1000 850ACS800-207LC-0860-7 2×R8i 2003 400 644 1400 1500ACS800-207LC-1120-7 2×R8i 2003 400 644 1400 1500ACS800-207LC-1670-7 3×R8i 2003 400 644 1700 1750ACS800-207LC-2200-7 4×R8i 2003 400 644 2200 2450ACS800-207LC-3270-7 6×R8i 2003 400 644 2800 2950ACS800-207LC-4360-7 8×R8i 2003 400 644 4200 3650ACS800-207LC-4900-7 9×R8i 2003 400 644 4300 4400ACS800-207LC-5450-7 10×R8i 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-upSeen 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

1×R8i units 0540-3, 0620-5ACU1 - 400/600 5ICU1 - 600 45ADU1 - 200 60RFI1 - 300 65LCL1 - 300 90ISU1* 1×R8i 300 951×R8i all units except 0540-3, 0620-5 1)ACU1 - 400/600 5ICU1 - 400 55RFI1 - 300 65LCL1 - 300 90ISU1* 1×R8i 300 952×R8i all 400V and 500V unitsACU1 - 400/600 5ICU1 - 600 45ADU1 - 200 60LCL1 - 300 120ISU1* 2×R8i 500 1252×R8i all 690V unitsACU1 - 400/600 5ICU1 - 600 45ADU1 - 200 60RFI1 - 300 65LCL1 - 300 120ISU1* 2×R8i 500 1253×R8i all 400V and 500V unitsACU1 - 400/600 5ICU1 - 600 45ADU1 - 200 60LCL1 - 300 70ISU1* 1×R8i 300 75LCL2 - 300 80ISU2 1×R8i 300 85LCL3 - 300 90ISU3 1×R8i 300 95

3×R8i all 690V unitsACU1 - 400/600 5ICU1 - 600 45ADU1 - 200 60LCL1 - 400 140ISU1* 3×R8i 700 1454×R8i all unitsACU1 - 400/600 5ICU1 - 600 45ADU1 - 200 60LCL1 - 300 100ISU1* 2×R8i 500 105LCL2 - 300 120ISU2 2×R8i 500 1256×R8i all 400V and 500V unitsACU1 - 400/600 5LCL1 - 300 10ISU1* 2×R8i 500 15ADU2 - 200 40ICU1 - 1000 50ADU1 - 200 60LCL2 - 300 100ISU2 2×R8i 500 105LCL3 - 300 120ISU3 2×R8i 500 1256×R8i all 690V unitsACU1 - 400/600 5ICU1 - 600 45ADU1 - 200 60LCL1 - 400 130ISU1* 3×R8i 700 135LCL2 - 400 140ISU2 3×R8i 700 145


Width Index

8×R8i 690V onlyACU1 - 400/600 5LCL1 - 300 10ISU1* 2×R8i 500 15LCL2 - 300 20ISU2 2×R8i 500 25ADU2 - 200 40ICU1 - 1000 50ADU1 - 200 60LCL3 - 300 100ISU3 2×R8i 500 105LCL4 - 300 120ISU4 2×R8i 500 1259×R8i 690V onlyACU1 - 400/600 5LCL1 - 400 30ISU1* 3×R8i 700 35ADU2 - 200 40ICU1 - 1000 50ADU1 - 200 60LCL2 - 400 130ISU2 3×R8i 700 135LCL3 - 400 140ISU3 3×R8i 700 14510×R8i 690V onlyACU1 - 400/600 5LCL1 - 300 10ISU1* 2×R8i 500 15LCL2 - 300 20ISU2 2×R8i 500 25ADU2 - 200 40ICU1 - 1000 50ADU1 - 200 60LCL3 - 300 100ISU3 2×R8i 500 105LCL4 - 300 110ISU4 2×R8i 500 115LCL5 - 300 120ISU5 2×R8i 500 125

00503842.xls A-8


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 codeACU Auxiliary control cubicle. Included with option +Z010 or +Z020ADU Adapter cubicle. Included with top cable entry option. +H351ICU Incoming cubicle. Included with main breaker or contactor option. +F250 or +F255ISU Supply module cubicle -LCL LCL filter cubicle -R8i IGBT supply module, frame size R8i -RFI1 RFI filter cubicle. Included with RFI filter option. +E202


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What this chapter containsThis chapter contains specifications of the inputs and outputs of the RMIO board.

To which board type and revisions this chapter appliesThis chapter applies to RMIO-01 board from revision J onwards and RMIO-02 board from revision H onwards.

RMIO board specifications

Analogue inputsWith Standard Application Program two programmable differential current inputs (0 mA / 4 mA... 20 mA, Rin = 100 ohm) and one programmable differential voltage input (-10 V / 0 V / 2 V... +10 V, Rin = 200 kohm).The analogue inputs are galvanically isolated as a group.

Isolation test voltage 500 V AC, 1 min.Max. common mode voltage between the channels

±15 V DC

Common mode rejection ratio > 60 dB at 50 HzResolution 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 outputVoltage +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 mAApplicable potentiometer 1 kohm to 10 kohm

Auxiliary power outputVoltage 24 V DC ± 10%, short circuit proofMaximum current 250 mA (shared between this output and optional modules installed on the RMIO)

Analogue outputsTwo programmable current outputs: 0 (4) to 20 mA, RL < 700 ohm

Resolution 0.1% (10 bit)Inaccuracy ± 1% (Full Scale Range) at 25 °C (77°F). Temperature coefficient: ± 200 ppm/°C

(± 111 ppm/°F) max.


90

Digital inputsWith 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 mAFiltering time constant 1 ms

Relay outputsThree programmable relay outputs

Switching capacity 8 A at 24 V DC or 250 V AC, 0.4 A at 120 V DCMinimum continuous current 5 mA rms at 24 V DCMaximum continuous current 2 A rmsIsolation test voltage 4 kV AC, 1 minute

DDCS fibre optic linkWith optional communication adapter module RDCO. Protocol: DDCS (ABB Distributed Drives Communication System)

24 V DC power inputVoltage 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

X201 VREF-2 AGND

X211 VREF+2 AGND3 AI1+4 AI1-5 AI2+6 AI2-7 AI3+8 AI3-

9 AO1+10 AO1-11 AO2+12 AO2-X221 DI12 DI23 DI34 DI4

9 DGND1

5 DI56 DI67 +24VD8 +24VD

11 DIIL

10 DGND2X231 +24 V2 GNDX251 RO12 RO13 RO1X261 RO22 RO23 RO2X271 RO32 RO33 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 DI1�DI4 and DI5/DI6/DIIL are separate (isolation voltage 50 V).

Ground

(Test voltage: 4 kV AC)


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What this chapter containsThis 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.


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3AFE

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2092

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: 30.

03.2

007

ABB OyAC DrivesP.O. Box 184FI-00381 HELSINKIFINLANDTelephone +358 10 22 11Fax +358 10 22 22681Internet www.abb.com

ABB Inc.Automation TechnologiesDrives & Motors16250 West Glendale DriveNew Berlin, WI 53151USATelephone 262 785-3200

800-HELP-365Fax 262 780-5135

ABB Beijing Drive Systems Co. Ltd.No. 1, Block D, A-10 Jiuxianqiao BeiluChaoyang DistrictBeijing, P.R. China, 100015Telephone +86 10 5821 7788Fax +86 10 5821 7618Internet www.abb.com

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Acs800 207lc Hw Manual Rev A

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