Acs800-207 Cabinet Installed Igbt Supply Units Master PDF

"Uncontrolled Copy"
ACS800
Hardware Manual
ACS800-207 Cabinet-installed IGBT Supply Units
"Uncontrolled Copy"
ACS800 Multidrive Manuals
Codes refer to English manuals.
General drive manuals (in all deliveries)

ACS800 Multidrive Safety Instructions (3AFE64760432)
ACS800 Multidrive Mechanical Installation (3AFE68233402)
ACS800 Multidrive Planning the Electrical Installation
(3AFE64783742)
Line-side converter manuals (delivered with the converter)
ACS800-307 and ACS800-507 Cabinet-installed Diode Supply Unit
User’s Manual (3AFE68279364)
ACS800-207 Cabinet-installed IGBT Supply Unit Hardware Manual
(3AFE68233810)
ACS800 IGBT Supply Control Program Firmware Manual
(3AFE68315735)
Motor-side converter hardware manuals
ACS800-107 Inverter Unit Hardware Manual (3AFE68233453) (in all
deliveries)
ASFC Switch Fuse Control Unit Hardware Manual (3AFE68441111)
(delivered with ASFC)
Motor-side converter firmware manuals, supplements and guides
(delivered with program)
ACS800 System Application Program Firmware Manual
ACS800 Standard Application Program Firmware Manual
(3AFE64527592) and Adaptive Program Application Guide
(3AFE64527274)
Crane Control Program Firmware Manual (3BSE11179)
Master/Follower Application Guide (3AFE64590430)
Pump Control Application Program Firmware Manual
(3AFE68478952)
Extruder Control Program Supplement (3AFE64648543)
Centrifuge Control Program Supplement (3AFE64667246)
Traverse Control Program Supplement (3AFE64618334)
etc.
Option device manuals (delivered with optional equipment)
RAIO-01 Analogue I/O Extension User's Manual (3AFE64484567)
RDIO-01 Digital I/O Extension User's Manual (3AFE64485733)
etc.
"Uncontrolled Copy"
ACS800-207
Cabinet-installed IGBT Supply Units
Hardware Manual
3AFE68233810 Rev B
EN
EFFECTIVE: 30.12.2005
 2005 ABB Oy. All Rights Reserved.

"Uncontrolled Copy"
"Uncontrolled Copy"
5
Table of contents
ACS800 Multidrive Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table of contents
About this manual

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Reader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Categorization according to frame sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Other documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
How the IGBT supply unit operates

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
AC voltage and current waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hardware description
Layout of an ACS800 multidrive with an IGBT supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Supply with frame R7i module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Supply with two frame R8i modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Single-line diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Supply with one frame R7i or R8i module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Supply with two frame R8i modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
IGBT supply module, frame R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Single-line diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Module layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
IGBT supply module, frame R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Single-line diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
LCL filter module types ALCL-04-05, -05-05, -04-07 or -05-07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
LCL filter modules types ALCL_1x_x and ACLC_2x_x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Control connections to the RDCU (RMIO board) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Type code of cabinet-installed IGBT Supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Basic code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Option codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Table of contents
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6
IGBT supply module type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Basic code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Option codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Type code of LCL filter module ALCL-04-05, -05-05, -04-07, -05-07 . . . . . . . . . . . . . . . . . . . . . . . 28
Basic code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Option codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Electrical installation
Checking the insulation of the assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Power connections for cabinet-installed IGBT supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Unit equipped with frame R7i module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Unit equipped with R8i module(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Control connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Installation of optional modules and PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Fibre optic links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Connections and tap settings of the auxiliary voltage transformer . . . . . . . . . . . . . . . . . . . . . . . . . 36
Start-up
Installation check-list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Basic checks with no voltage connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Connecting voltage to input terminals and auxiliary circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Starting the IGBT supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Checks after start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
On-load checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Setting parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Maintenance
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Cleaning the heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Checking and replacing the air filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Checking and cleaning the power connections via quick connector . . . . . . . . . . . . . . . . . . . . . . . 43
Replacing and reforming the capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Capacitor replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Replacing the cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Supply module, frame size R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Supply module, frame size R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Table of contents
"Uncontrolled Copy"
7
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
LCL filter type ISU_LCL_5R7 and -6R7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
LCL filter type ALCL-1x and -2x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Replacing the supply module, frame size R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Replacing the supply module, frame size R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Removing the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Inserting the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Redundancy (Reduced run capability) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Technical data - ACS800-207

Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Dimensions, weight, noise, losses, air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Air inlet and outlet filter type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Input power cable lead-through size and terminal sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Supply unit equipped with R7i module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Supply unit equipped with R8i module(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Standards and markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Other data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Technical data - ACS800-104 IGBT supply module

Type equivalence table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
LCL filter types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
AC and DC fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
IGBT supply module capacitance, dimensions and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
LCL filter dimensions, weight and air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Power losses: IGBT supply module and LCL filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
IGBT supply unit cooling characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Cable terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Input power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Output connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
RMIO board specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Analogue inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Constant voltage output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Table of contents
"Uncontrolled Copy"
8
Auxiliary power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Analogue outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
DDCS fibre optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
24 VDC power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Power consumption of auxiliary devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Cooling fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
US patents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
IGBT supply unit example circuit diagrams

Supply unit with module R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Drive with 2×R8i supply and 2×R8i inverter modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Table of contents
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About this manual
What this chapter contains

This chapter gives information on the manual.
Compatibility
The manual is compatible with the cabinet-installed IGBT supply units (ACS800-
207). Some chapters are also valid for ACS800-104 IGBT modules to be installed
into cabinet by the user.
Safety instructions
Follow all safety instructions delivered with the drive.
• Read the complete safety instructions before you install, commission, or use
the drive. The complete safety instructions are given in ACS800 Multidrive Safety
Instructions (3AFE64760432 [English])
• Read the software function specific warnings and notes before changing the
default settings of the function. For each function, the warnings and notes are
given in the section describing the related user-adjustable parameters.
• Read task specific safety instructions before starting the task. See the section
describing the task.
Reader
The reader is expected to know the standard electrical wiring practices, electronic
components, and electrical schematic symbols.
Contents
• How the IGBT supply unit operates
• Hardware description
• Electrical installation
• Start-up
• Maintenance
• Technical data - ACS800-207
• Technical data - ACS800-104 IGBT supply module
• IGBT supply unit example circuit diagrams
About this manual

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Categorization according to frame sizes

Some descriptions, instructions, technical data and dimensional drawings which
concern only a certain group of units may be marked with the symbol of the frame
size (such as “R2i”, “4×R8i”, etc.). The marking derives from the basic construction
of the IGBT supply modules that form the supply unit.
The frame size is not marked on the type designation labels. To identify the frame
size of an inverter unit, see the rating tables in chapter Technical data -
ACS800-207.
Other documents
User documentation of a multidrive delivery contains technical drawings and a set of
manuals. Technical drawings are tailor-made for each delivery. The composition of
the manual set depends on the composition of the drive.
The manuals are listed below. The codes refer to the original English manuals.
Manual Included in …
General drive manuals
• ACS800 Multidrive Safety Instructions (3AFE64760432) every delivery
• ACS800 Multidrive Mechanical Installation (3AFE68233402)
• ACS800 Multidrive Planning the Electrical Installation (3AFE64783742)
Line-side converter manuals
• ACS800-307 and -507 Diode Supply Unit User’s Manual (3AFE64494023) delivery which
• ACS800-207 IGBT Supply Unit Hardware Manual (3AFE68233810) includes the
corresponding
• ACS800 IGBT Supply Control Program Firmware Manual (3AFE68315735) supply module
Motor side-converter hardware manual every delivery
• ACS800-107 Inverter Unit Hardware Manual
Motor side-converter firmware manuals
• ACS800 System Application Program Firmware Manual delivery which
• ACS800 Standard Application Program Firmware Manual (3AFE64527592) includes the
and Adaptive Program Application Guide (3AFE64527274) corresponding
program
• ACS800 Master/Follower Application Guide (3AFE 64590430)
• ACS800 PFC Application Program Firmware Manual (3AFE64649337)
• ACS800 Crane Application Program 7.x Firmware Manual (3BSE 11179)
… etc.
Option device manuals
• RAIO-01 Analogue I/O Extension User's Manual (3AFE64484567) delivery which
• RDIO-01 Digital I/O Extension User's Manual (3AFE64485733) includes the
corresponding
… etc. option device
About this manual

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This chapter describes how the IGBT supply unit operates. 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.
Operation principle
The IGBT supply unit consists of an IGBT supply module, a line filter (LCL filter), AC
and DC fuses and optional devices. 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.
AC fuses Line filter IGBT supply module DC fuses
AC input DC output

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AC voltage and current waveforms

The AC current is sinusoidal at a unity power factor. The IGBT supply unit does not
generate characteristic current or voltage overtones like a traditional 6- or 12-pulse
bridge does.
The Total Harmonic Distortion (THD) in voltage depends slightly on the Short Circuit
Ratio in the Point of Common Coupling (PCC). See chapter Technical data -
ACS800-104 IGBT supply module. The high-frequency switching slightly distort the
voltage waveform at the input of the converter. The depth of the voltage notches
depends on the ratio of supply line inductance to total line inductance (supply line +
LCL filter inductance).
Typical line current (iU) and voltage (uUV) waveforms are shown below.
I [A], U [VAC]
1200 uUV
800
iU
400
0 t [ms]
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38
-400
-800
-1200
A typical spectrum of the voltage distortion at the output of the transformer is shown
below. Each harmonic is presented as compared to fundamental voltage (reference
value = 1). n denotes the ordinal number of the harmonic.
THD Voltage [%]

2
1,5
0,5
0 No. of harmonic
THD 11 21 31 41 51 61 71 81 91 101 111 121 131 141 151 161 171 181 191

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This chapter describes the hardware of the IGBT supply unit. 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.
Layout of an ACS800 multidrive with an IGBT supply unit
Supply with frame R7i module

The figure below shows the layout of an ACS800 multidrive equipped with an IGBT
supply unit. This is an example of a drive equipped with supply module of frame size
R7i and some commonly used options. The designations in brackets [ ] refer to
Single-line diagrams below.
Doors closed
A B C
Description
1 A Auxiliary control cabinet
1. Auxiliary circuit switch-fuse [Q10]
2. Meters, main breaker control switch, emergency stop switch
3. Auxiliary voltage transformer (230 or 115 VAC) [T10]
2 4. Swing-out frame with auxiliary control relays, circuit breakers, etc.
5. IGBT supply module control unit [RDCU]
B IGBT supply module cabinet

6. Input power cable and PE terminals
7. Main switch, disconnector and AC fuses [Q1]
8. Main contactor [K1]
9. LCL line filter [LCL]
10. IGBT supply module [ACS800-104]
11. DC fuses [F1]
Doors open 12. Charging contactor [K2]
13. Charging resistor [R]
7 C Inverter cabinet(s): See ACS800-107 Hardware

Manual (3AFE68233453 [English])
11
8 13
5 10
12
4
6
9
3
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Supply with two frame R8i modules

The figure below shows the layout of an ACS800 multidrive equipped with an IGBT
supply unit. This is an example of a drive equipped with supply modules of frame
size R8i and some commonly used options. The designations in brackets [ ] refer to
Single-line diagrams below.
Doors closed
A B C D E
Description
1 A Auxiliary control cabinet
1. Auxiliary circuit switch-fuse [Q10]
9
2. Meters, main breaker control switch, emergency stop switch
3. Auxiliary voltage transformer (230 or 115 VAC) [T10]
2 4. Swing-out frame with auxiliary control relays, circuit breakers, etc.
5. IGBT supply module control unit [RDCU] and branching unit
8 [APBU]
B Incoming cabinet
6. Input power cable and PE terminals
7. IGBT supply charging resistors and contactor [K2, R]
8. Withdrawable main circuit breaker [Q1]
9. Grounding switch [Q9]
Doors open C IGBT supply module cabinet

10. AC fuses [F2]
10 11. LCL line filter [LCL]
12. IGBT supply module [ACS800-104]
13. DC fuses [F1]
13 13
D Inverter cabinet: See ACS800-107 Hardware Manual
(3AFE68233453 [English])
5 12 11 12 E Inverter control cabinet: See ACS800-107 Hardware
Manual (3AFE68233453 [English])
4
6
3 7
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Single-line diagrams
Supply with one frame R7i or R8i module

Supply
transformer ACS800
LCL -104
Q1 K1 F1
~ DC supply for
inverters
F20 =
Q10
4
K2 R
1) Power supply for LCL filter and IGBT

supply module fans (module R8i: only T10 n
with constant speed fan)
2) Temperature supervision
3) Module control via fibre optic link 1)
Control circuitry 2) 3)
1
0
START RMIO
board
Supply with two frame R8i modules

For a more detailed presentation of the wiring, see chapter IGBT supply unit
example circuit diagrams.
Supply
transformer 2×ACS800
U< -104
Q1 F2 LCL F1
~
= DC supply for
Q10 F20 inverters
Q9 ~
4
=
K2 R
T10
1) Power supply for IGBT supply module
fan (only with constant speed fan) 1) n
2) Power supply for LCL filter module fan
3) Temperature supervision
4) Module control via fibre optic link
2)
Fan on/off control and temperature
supervision (only with constant speed Control circuitry 3) 4)
fan)
1
0
START RMIO APBU
board board
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IGBT supply module, frame R7i
Single-line diagram
3 2
2 No. Marking Explanation
7
1 U2…W2 Power input busbars (3 phase AC)
2 2 +, - Power output busbars (DC)
6 3 X50 Socket for fan control. Not in use.
4 X41 Socket for fan power supply
5 Cooling fan
6 V1,V2 Fibre optic connectors for control board

(external)
5
4 7 Socket for prevention of unexpected start-
I up circuit. Not in use.
M I
~1
1 Module connects to the cabinet ground busbar via the fixing bolts
3 and the cabinet frame.
Module layout
The figure below shows the IGBT supply module. The control unit (type RDCU)
containing the RMIO board is external (not shown).
2 No. Explanation
2
1 Power input busbars (3 phase AC)
3
2 Power output busbars (DC)
7 3 Socket for fan control. Not in use.
4 Socket for fan power supply
5 Cooling fan
6 Fibre optic connectors for control board (external)

6
7 Socket for prevention of unexpected start-up circuit. Not
in use.
1
4
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Printed circuit boards

The figure below illustrates the interconnections between the boards.
IGBT supply module

NRED
Intermediate
DC link input 1 X4
2
3 X2 AINT APOW RDCU
X1
RMIO 1)
X8 X2
X34 24 V
AGDR
IGBT control
pulses X10 X1 X1
X2 X2
X3 X3
V1 V68
Phase current
X7 V2 V57
measurements
(3)
M
1~
Fan power supply

230 VAC (115 VAC)
X41
Item Explanation
RDCU Drive control unit
RMIO Converter control board
APOW Power supply board
NRED Voltage reduction board (in 690 VAC units only)
AINT Main circuit interface board
AGDR Gate driver board
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.
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IGBT supply module, frame R8i
General
Modules of frame size R8i are used to achieve output powers from 200 kW upwards.
It can be used in single or parallel configurations. The module runs on wheels, and it
can easily be removed from the cabinet for service.
Single-line diagram
2
5 4 No. Connection/measurement
n
1 (U2, Quick connector for power input (3 phase AC)
2 V2, W2)
3 2 Current transformers (one for each phase for

current measurement)
3 (V1,V2) Fibre optic connectors for control board

connection (to RMIO, or to RMIO via branching
unit APBU)
4 (X50) Quick connector for cooling fan power supply

(when no fan speed control in use)
M I 5 (+, -) Busbars for power output connections (DC)

~3 I 2
1 Module connects to the cabinet ground busbar via the fixing bolts
and the cabinet frame.
3
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Layout
The figure below shows the IGBT supply module. The control unit (type RDCU)
containing the RMIO board is external (not shown).
5
2
Item Explanation
1 DC (output) connections
2 Input busbars. To be aligned with the quick connector socket mounted in the cabinet.
Direct connection of cables without using a quick connector is also possible.
3 Fibre optic connectors of the AINT board. Connected to the RDCU drive control unit (via
an NPBU/APBU branching unit in case of parallel modules).
4 Retractable support legs
5 Handle
6 Cooling fan
7 Socket for cooling fan power supply and control (only for a constant speed fan)
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Printed circuit boards

The figure below illustrates the interconnections between the boards.
IGBT supply module

NRED
Intermediate
DC link input 1 2
2
3 4 AINT APOW RDCU
X1
RMIO 2)
X8 X2 X2
X34 24 V
AGDR
IGBT control AGDR
pulses X10 AGDR
X2 X1
X10 X2 X2
X10 X2
X3
V1 V68
Phase current
X7 V2 V57
measurements
(3) V5
AFPS AFIN
Intermediate M
DC link input X1 X2 X1 X2 3~
2
V1
(1
Fan power
supply and X50
control
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 Converter control board
APOW Power supply board
NRED Voltage reduction board (in 690 VAC units only)
AINT Main circuit interface board
AGDR Gate driver board
AFPS Power supply for inverter feeding motor of module fan (only in units with speed-controlled
fan)
AFIN Inverter feeding motor of module fan (only in units with speed-controlled fan)
1)
Fan power supply alternatives: Constant speed fan has an external power supply via X50. Speed-
controlled fan is supplied from module DC via an inverter.
2)
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.
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LCL filter module types ALCL-04-05, -05-05, -04-07 or -05-07

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.
See chapter Technical data - ACS800-104 IGBT supply module, page 57, for the
IGBT supply units which are equipped with filter ALCL-04-05, -05-05, -04-07 or
-05-07.
Item Explanation
4 1 AC input busbars
2
2 AC output busbars
3 Cooling fan
4 Terminal for module temperature

supervision and fan power supply
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LCL filter modules types ALCL_1x_x and ACLC_2x_x

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.
Filter modules run on wheels. They can easily be removed from the cabinet for
service.
See chapter Technical data - ACS800-104 IGBT supply module, page 57, for the
IGBT supply units which are equipped with filter types ALCL_1x_x or ACLC_2x_x.
ALCL_1x_x ALCL_2x_x
3
1 1
3
4
2
4
Item Explanation
1 AC input busbars
2 AC output terminals: ALCL_1x_1x: counterpart for a quick connector socket,

ALCL_2x_x: busbars
3 Socket for fan power supply and module temperature supervision
4 Cooling fan
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Control interfaces
The following diagram shows the control interfaces and I/O options of the supply
unit.
Drive Control Unit

(RDCU)
Parameter setting and Optional module 1: Fieldbus adapter (e.g.

Motor Control
diagnostics through RMBA, RDNA, RPBA)
and I/O Board
CDP 312R Control Panel
(RMIO)
and related accessories
Optional module 2: Not in use when the

board controls an IGBT supply module.
Em. stop
1 Reset Optional module 3: DDCS communication
St option (RDCO-0x)
0
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).
Supply unit control circuitry
including door switches, charging
circuit control, main contactor
control, etc.
Input power
= ~ To motor
~ =
Supply unit Inverter unit
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Control connections to the RDCU (RMIO board)
Terminal block size: X20

2
cables 0.3 to 3.3 mm (22 to 12 AWG) 1 VREF- Reference voltage -10 VDC, 1 kohm < RL <
2 AGND 10 kohm
Tightening torque:
X21
0.2 to 0.4 Nm (0.2 to 0.3 lb.ft)
1 VREF+ Reference voltage 10 VDC, 1 kohm < RL <
2 AGND 10 kohm
Control circuitry 3 AI1+ Not in use. 0(2)…10 V, Rin > 200 kohm
Operating switch Reset button 4 AI1-
1 3 X1 13
5 AI2+ Not in use. 0(4)…20 mA, Rin = 100 ohm
6 AI2-
7 AI3+ Not in use. 0(4)…20 mA, Rin = 100 ohm
2 4 X2 14
8 AI3-
0 0
1 1 9 AO1+ Not in use. 0(4)…20 mA, RL < 700 ohm
START
10 AO1-
Main contactor 11 AO2+ Output current 0(4)…20 mA, RL < 700 ohm
12 AO2-
X22
1 DI1 LCL filter temperature supervision
2 DI2 Supply unit Stop/Start
Charging contactor
3 DI3 Main contactor supervision
4 DI4 Not in use
°t
5 DI5 Not in use
6 DI6 Reset ( )
For details, see the delivery specific 7 +24V +24 VDC max. 100 mA
circuit diagrams of the cabinet-installed 8 +24V
unit, or chapter IGBT supply unit 9 DGND1 Digital ground
example circuit diagrams. The diagrams
10 DGND2 Digital ground
show:
11 DIIL Not in use
- supply unit stop/start control
- main contactor supervision and on/off X23
control 1 +24V Auxiliary voltage output, non-isolated,
- fan power supply 2 GND 24 VDC 250 mA
- charging contactor On/Off control X25
- LCL filter temperature supervision. 1 RO1 Relay output 1: Charging contactor
WARNING! Never force the main 2 RO1 control
contactor closed before charging has 3 RO1
been completed. Starting sequence, i.e.
X26
charging, acknowledgements, main
contactor control and start of the IGBT 1 RO2 Relay output 2: Fault
supply module, follows a certain order. 2 RO2
Never change the order by by-passing 3 RO2
signals (using jumpers), etc. That will X27
cause a malfunction that may damage
1 RO3 Relay output 3: Main contactor
the unit.
2 RO3 control
3 RO3
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Type code of cabinet-installed IGBT Supply unit

Type code describes the composition of the unit in short. The type code is visible on
the name plate (sticker) which is attached to the cabinet. The complete code is
divided in sub-codes:
• The first 17 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
Digit no. Name Alternatives Description
1…6 Product series ACS800
8…10 Construction 207 IGBT Supply Unit
12…15 Size xxxx
17 Voltage rating 3 380…415 V
5 380…500 V
7 380…690 V
Option codes
This is a common list for the ACS800 supply units. Not all options are available/used
for the IGBT Supply Unit (ACS800-207).
Category Value Description
Input B052 IP21, UL type 1, NEMA 1
B053 IP22, UL type 1, NEMA 1
B054 IP42, UL type 1, NEMA 1
B055 IP54, UL type 12, NEMA12
Degree of C121 Marine Construction
protection C128 Cooling air through bottom
C129 UL-approved components-approved components
C130 Channelled Air Outlet
C134 CSA
Construction E202 EMC/RFI-filter modules
E210 2nd Environment
Line options F250 Line Contactor
F251 Fuses
F253 Disconnector
F254 Switch Fuse
F255 Circuit Breaker (SACE)
F259 Earthing Switch
Cabinet G300 Cabinet Heater
options G301 Cabinet Lightning
G304 115 VAC
G307 Terminals for External Control Voltage
G314 Aluminium
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Category Value Description

G315 Tin plated copper
G316 Cable Supply Conductors
G317 Busbar Supply Conductors
G320 230 VAC
G330 Halogen Free Wiring
G331 Emergency Stop Push button on the door (red)
G332 Electrical disconnect push button on the door (black)
G333 kW-meter
G334 V-meter with selector switch
G335 A-meter in one phase
G336 Arc monitoring
G337 Arc monitoring with current sensing unit
G343 Corrosion Coupon in ACU
Cabling H350 Bottom Entry
H351 Top Entry
H358 Cable gland plates (Steel 3mm)
H364 Cable gland plates (Aluminium 3mm)
H365 Cable gland plates (Brass 6mm)
H367 Control cable Bottom
H368 Control cable Top
Man machine J400 Control Panel CDP 312R
interface J401 Drive Monitoring Display
J411 Remote Supply Control
Fieldbus K450 Panel Bus selected
K451 RDNA-01 (DeviceNet)
K452 RLON-01 (LONWorks)
K453 NIBA-01 (Interbus-S)
K454 RPBA-01 (Profibus)
K455 NMBP-01 (Modbus Plus)
K456 NAFA-01 (AF100)
K457 NCAN-02 (CANOpen)
K458 RMBA-01 (Modbus)
K458 RMBA-01 (Modbus)
K459 NCSA-01
K462 RCNA-01 (Control Net)
K464 RETA-01 (Ethernet)
I/O L508 DDCS Communication 1
L509 DDCS Communication 2
Specialities P902 Customised (Additional information needed)
Safety Q951 Emergency Stop, Stop Category 0
features Q952 Emergency Stop, Stop Category 1
Q953 Earth Fault Monitoring, Earthed Mains TN
Q954 Earth Fault Monitoring, Unearthed Mains IT
Q959 Supply transformer breaker disconnect push button (red) on the door
Q961 Safety Category 3
Q962 Safety Category 1
Manual R700 English
language R701 German
R702 Italian
R705 Swedish
R706 Finnish
R707 French
R708 Spanish
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IGBT supply module type code

Each module has a type designation label attached, containing e.g. the type code of
the unit. The type code contains information on the specifications and configuration
of the unit.
unit. The fields in the basic code are separated by hyphens.
The main selections are described below. All options are not available for all types.
For more information, contact your local ABB representative.
Basic code
Digit no. Name/Description Alternatives Description
1…6 Product series ACS800
8…10 Construction 104 Inverter module (or rectifier module)
12…15 Size 0100 and up Size 100 and up
17 Voltage rating 3 380/400/415 V. Nominal voltage: 400 V.
5 440/460/480/500 V. Nominal voltage: 500 V.
7 525/575/600/660/690 V. Nominal voltage: 690 V.
Option codes
Ident. Name/Description Alternatives Description
letter
A Supply frequency A013 60 Hz
C Cooling fan control C126 Speed-controlled cooling fan supplied from the
DC bus. Frame R8i only.
E Filters E205 Internal (du/dt) filters. This feature is standard.

Frames R8i and n×R8i only.
G Supply voltage for G304 115 VAC

fan
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Type code of LCL filter module ALCL-04-05, -05-05, -04-07, -05-07

Each module has a type designation label attached, containing e.g. the type code of
the unit. The type code contains information on the specifications and configuration
of the unit.
unit. The fields in the basic code are separated by hyphens.
The selections are described below.
Basic code
Digit no. Name/Description Alternatives Description
1…4 Product series ALCL LCL filter
6,7 Size 03,…,05 Size
9,10 Voltage rating 05 380…500 V. Nominal voltage: 500 V.
07 525…690 V. Nominal voltage: 690 V.
Option codes
Ident. Name/Description Alternatives Description
letter
A Supply frequency A013 60 Hz
G Supply voltage for G304 115 VAC

fan
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This chapter instructs how to check the insulation of the assembly and how to install
the input power cables and control cables. The information is valid for cabinet-
installed IGBT supply units (ACS800-207), and IGBT supply modules (ACS800-104)
if they are equipped with similar auxiliary devices.
For information on the installation planning, i.e. cable selection, protections, etc., see
ACS 800 Multidrive, Planning the Electrical Installation (3AFE 64783751 [English]).
Checking the insulation of the assembly

Check the insulation of the input power cables before connecting them to the drive.
Every drive module has been tested for insulation between the main circuit and the
chassis 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.
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Power connections for cabinet-installed IGBT supply unit
Unit equipped with frame R7i module

Connection diagram
Q1 K1
L1
L2 ~
L3
=
PE
Connection procedure
Release the handle and open the door of the cabinet.
Remove the shrouds that protect the input busbars and cable lead-through.
Lead the cables into the cabinet and connect:
• Twist the cable shields to bundles and connect to cabinet PE (ground) busbar.
Connect the separate ground conductors/cables (if exist) to cabinet PE (ground)
busbar.(1) For minimal interference, it is a recommended practise to run the cable
unstripped up to the phase busbars and ground the cable shield 360 degrees.(2)
• Connect the phase conductors to the input power terminals.(3) Tightening
torque = 70 Nm [55 lb.ft].
Replace the shrouds and close the door.
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Converter cubicle
Door open, shrouds removed
Recommendation: 360°
grounding of the cable shield at
the lead-through suppresses
interference.
3
2
3
PE
PE
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Unit equipped with R8i module(s)

Connection diagram
U<
Q1
L1
L2 ~
L3
=
PE
Release the handle and open the door of the incoming cabinet. (See chapter
Hardware description.)
Remove the shrouds that protect the input busbars and cable lead-through.
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 ground conductors/cables (if exist) to cabinet PE (ground)
busbar.
• Connect the phase conductors to the input power terminals. Tightening
torque = 70 Nm [55 lb.ft].
• Replace the protecting shrouds and close the door.
Recommendation: 360° grounding of

the cable shield at the lead-through
suppresses interference.
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Control connections
General
Typically, 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 used or 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.
• read the fault indication through a relay output
• communicate with the unit through a serial communication interface.
See the circuit diagrams delivered with the unit for the default control connections
and the connection terminals.
If additional control cables need to be installed, proceed as follows:
Disconnect the main circuit from power supply and open the auxiliary circuit switch-disconnector.
Release the door handle and open the door of the control and I/O cabinet.
Remove the two locking screws at the edge of the swing-out frame and open the frame.
Run the cables into the inside of the cabinet through the grommets provided.
Top entry units only: If several cables need to be run through one grommet, use Loctite 5221 (cat. no.
25551) under the grommet to seal the cable entry.
Units with EMI conductive cushions only:

Run the cables between the cushions as shown below. Strip the cable at this location to enable proper
connection of the bare shield and the cushions. Tighten the cushions firmly onto the cable shields.
Side view
Strain relief EMI conductive
cushions
Grommet Lead-through plate
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If the outer surface of a cable shield is non-conductive, turn the shield inside out as shown below and
apply copper foil to keep the shielding continuous. Do not cut the grounding wire (if present).
Stripped cable Conductive surface of Stripped part covered

the shield exposed with copper foil
Copper foil
Cable shield Shielded twisted pair
Grounding wire
Sort the cables so that the thinnest and thickest cables are at opposite ends of the opening.
Top view
Thickest cable Thinnest cable
Run the cables to the swing-out frame as shown below. Wherever possible, use the existing cable trunking
(1) in the cabinet. Use sleeving wherever the cables are laid against sharp edges. Leave some slack in the
cable at the hinge (2) to allow the frame to open fully. Tie the cables to the braces (3) to provide strain
relief.
Note: Actual equipment may differ from what is shown below.
Swing-out frame open Cable routing example
3
1
Cut the cables to suitable length. Strip the cables and conductors.
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Twist the cable shields into bundles and connect them to the ground terminal nearest to the terminal block.
Keep the unshielded portion of the cables as short as possible.
Connect the conductors to appropriate terminals (see the circuit diagrams delivered with the unit).
Close the swing-out frame, refasten it, and close the doors.
Installation of optional modules and PC

Optional modules (such as fieldbus adapter, I/O extension module and the pulse
encoder interface) are inserted in the optional module slot of the RMIO board and
fixed with two screws. The slots on the RMIO are described in chapter Hardware
description, page 23. See the appropriate optional module manual for cable
connections.
Fibre optic links

DDCS fibre optic links are provided by the RDCO module (optional) for PC tools,
master/follower link, NDIO, NTAC, NAIO and fieldbus adapter modules of type Nxxx.
See RDCO User’s Manual for connections. Observe colour coding when installing
fibre optic cables: blue connectors go to blue terminals, and grey connectors to grey
terminals.
Connect multiple devices in a ring when connecting them to the same channel.
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Connections and tap settings of the auxiliary voltage transformer

The transformer voltage settings have been done at the factory as default. However,
it is a recommended practise to check the settings at the first start-up.
3~ Input
Primary
Secondary
Output
3~ input 1~ output 3~ output
Supply Tap settings Supply 230 V 115 V 400 V (50 Hz) 320 V (60 Hz)
Terminals
voltage A1 to... B1 to… C1 to… voltage Terminals Tap setting Terminals Tap setting Terminals Terminals
690 V A1, B1, C1 C2 A2 B2 690 V a3, n1 230– a4, n1 115– a1, b1, c1 a2, b2, c2
660 V A1, B1, C1 C2 A2 B2 660 V a3, n1 230+ a4, n1 115+ a1, b1, c1 a2, b2, c2
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Start-up

This chapter instructs how to perform the first start-up of the IGBT supply unit. 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.
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.
Action Additional information

Installation check-list
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 insulation resistance of the assembly is checked
according to instructions given in chapter Electrical installation.
Check that the mechanical and electrical installation of the drive is
inspected and OK.
Ensure that the surroundings and inside of the cabinet are free from dust After the start, the cooling air fans
and loose objects like cable trimmings and other waste left from the may suck nearby loose objects into
installation. the unit. This might cause failure and
damage the unit.
Basic checks with no voltage connected
If the cabinet-installed IGBT supply unit is equipped with an air circuit Optional device. See the delivery
breaker, check the current trip limits of the breaker (preset at the factory). specific circuit diagrams.
General rule
Ensure the selectivity condition is fulfilled i.e. the breaker trips at a lower
current than the protection device of the supply line, and that the limit is
high enough not to cause unnecessary trips.
Long term current limit
Rule of thumb: Set to the rated AC current of the supply unit.
Peak current limit
Rule of thumb: Set to a value 3-4 times the rated AC current of the supply
unit.
Units with parallel IGBT supply modules: By default, memory backup is
Locate the branching unit (APBU). Enable memory backup battery by switched off to save the battery.
setting the actuator 6 of switch S3 to ON.
Check the settings of the relays and breakers/switches of the auxiliary See delivery specific circuit diagrams.
circuits and switch the breakers on.
Check the voltage setting of the auxiliary voltage transformer. See chapter Electrical installation.
Start-up
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Disconnect the unfinished or unchecked 230/115 VAC cables that lead
from the terminal blocks to the outside of the equipment.
Connecting voltage to input terminals and auxiliary circuit
WARNING! When voltage is connected to the input terminals, the voltage
will also be connected to the auxiliary circuits - also those wired to motor-
side converter cabinet(s).
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 the motor terminal boxes are on
Open the grounding switch. Optional device. See delivery specific
Note: The grounding switch and the main disconnecting device are either circuit diagrams.
mechanically coupled or electrically interlocked: Grounding switch can be closed
only when the main disconnecting device is open. The disconnector can be closed
only when the grounding switch is open.
Close the main breaker of the supply transformer.
Close the auxiliary circuit switch-fuse. Optional device. See delivery specific
circuit diagrams.
Starting the IGBT supply unit
Close the main breaker and start the IGBT supply module:
- reset the starting logic by the RESET button on the cabinet door
- turn the starting switch on the cabinet door from position 0 to START
position for 2 seconds, release and leave it to position 1.
Checks after start
Check the correct operation of the emergency-stop circuits. Optional device. See delivery specific
circuit diagrams.
On-load checks
Check that the cooling fans of the IGBT supply modules and LCL filters The fan rotates noiselessly in the
rotate freely in the right direction. direction the arrow on the fan cover
points to.
Check the correct operation of the current and voltage meters. Optional device. See delivery specific
circuit diagrams.
IT (ungrounded) power systems with an earth (ground) fault protection based This is an optional feature (IRDH265-
on an insulation monitoring device: x). See the circuit diagrams delivered
with the device and ACS800 IGBT
Check the external earth fault detection is activated (parameter 30.04),
Supply Control Program Firmware
and the connection to digital input DI4.
Manual (3AFE68315735 [English]).
Check the tuning of the insulation monitoring device (Bender). See also IRDH265 Operating Manual
The device is tuned at the factory. by Bender (code: TGH1249).
TN (grounded) power system with earth (ground) fault protection based on This is a programmable feature. See
internal current measurement: ACS800 IGBT Supply Control
Program Firmware Manual
Check the earth fault level (parameter 30.02).
(3AFE68315735 [English]).
Start-up
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Setting parameters
Parameters of the IGBT supply module need not be set in a start-up ACS800 IGBT Supply Control
procedure or in normal use. Program Firmware Manual
Note: As default, no constant DC voltage reference is set for the IGBT supply unit (3AFE68315735 [English]).
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 line
Note: The control program performs an AC line identification routine every time
the control board is powered up. The routine takes 3 to 7 seconds, only after which
the supply 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.
Start-up
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Start-up
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Maintenance

This chapter contains a table of maintenance intervals, maintenance instructions.
and the descriptions of LEDs.
Maintenance intervals
If installed in an appropriate environment, the drive requires very little maintenance.
Routine maintenance intervals recommended by ABB are given below.
Interval Maintenance work Instruction / additional data
Every year of storage Capacitor reforming See document Capacitor Reforming Guide (Code:
3BFE 64059629 [English]).
Every 6 to 12 months Heatsink temperature check See section Cleaning the heatsink.
(depending on dustiness of and cleaning
environment)
Every year (IP22, IP22R, IP42 Air filter check, replacement if See section Checking and replacing the air filters.
and IP42R units) necessary
Every year (IP54 and IP54R Air filter replacement

units)
Every 3 years (frame R8i) Quick connector connection See section Checking and cleaning the power
surfaces check, cleaning and connections via quick connector.
greasing
Every 6 years IGBT supply module and LCL See section Replacing the cooling fans.
filter module cooling fan
change
Every 6 years (parallel- Memory backup battery Locate APBU unit. Switch off power to unit.
connected IGBT supply renewal of the APBU branching Remove cover. Replace battery with new CR 2032
modules) unit battery.
Every 10 years Capacitor renewal See Replacing and reforming the capacitors.
Maintenance
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Cleaning the heatsink

The heatsink fins pick up dust from the cooling air. Unclean heatsink may cause
overtemperature warnings and faults. In a “normal” environment (not especially
dusty nor clean) the heatsink should be checked annually, in a dusty environment
more often.
When necessary, clean the heatsink as follows:
WARNING! Read and follow the instructions in ACS800 Multidrive Safety

Instructions [3AFE64760432 (English)]. Ignoring the instructions can cause physical
injury or death, or damage to the equipment.
• Remove the module cooling fan (see section Replacing the cooling fans
on page 44).
• Blow dry clean compressed air from bottom to top and simultaneously use a
vacuum cleaner at the air outlet to trap the dust. Note: Prevent the dust from
entering adjoining equipment.
• Refit the cooling fan.
Checking and replacing the air filters

• Check the air filters and replace them if necessary. See chapter Technical data -
ACS800-207 for the correct filter types. To access the inlet (door) filters: remove
the fastener(s) at the top of the grille, lift the grille and pull it away from the door.
The outlet (roof) filter in IP54 units has a similar mechanism.
• Check the cleanliness of the cabinet. Clean the interior of the cabinet if necessary
using a soft brush and a vacuum cleaner.
• Close the cabinet doors.
Maintenance
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Checking and cleaning the power connections via quick connector

Quick connector is used at:
• AC input of IGBT supply module frame size R8i
• AC output of LCL filter module type ALCL_1x_1x.

• Extract the supply module from the cabinet. See section Replacing the supply
module, frame size R8i below.
• Check the tightness of the cable connections at the quick connector. See the
tightening torque table in chapter Technical data - ACS800-104 IGBT supply
module.
• 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.
• Re-insert the module.
• Repeat the procedure for all remaining modules.
Replacing and reforming the capacitors

The IGBT supply modules employ several electrolytic capacitors. Their life span is at
least 90 000 hours depending on the operating time of the drive, loading and
ambient temperature. Capacitor life can be prolonged by lowering the ambient
temperature.
It is not possible to predict capacitor failure. Capacitor failure is usually followed by
damage to the unit and an input cable fuse failure, or a fault trip. Contact ABB if
capacitor failure is suspected.
Reforming
Reform (re-age) spare part capacitors once a year according to Capacitor Reforming
Guide (code: 64059629 [English]), available from your local ABB representative.
Capacitor replacement
Contact an ABB service representative.
Maintenance
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Replacing the cooling fans
Supply module, frame size R7i

• Remove the shrouds in front of the IGBT module.

• Disconnect the wire plug (1).
• Remove the two screws holding the fan unit (2).
• Pull the fan unit slightly outwards, then downwards to free it (3).
• Install new fan in reverse order.
• For the IGBT supply module, reset the fan operating hour counter. See ACS800
IGBT Supply Control Program Firmware Manual (3AFE68315735 [English]).
Maintenance
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Supply module, frame size R8i

The life span of the cooling fans is about 60 000 hours. The actual life span depends
on the running time of the fan, ambient temperature and dust concentration.
Replacements are available from ABB. Do not use other than ABB specified spare
parts.
The supply unit control program registers the power-on time of the supply module.
See ACS800 IGBT Supply Control Program Firmware Manual (3AFE68315735
[English]).
Procedure

• Disconnect the fan wiring plug (1).

• Remove the locking screws (2).
• Pull the fan out along its sliding rails (3).
• Install a new fan in reverse order.
• For the IGBT supply module, reset the fan operating hour counter. See ACS800
IGBT Supply Control Program Firmware Manual (3AFE68315735 [English]).
Maintenance
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LCL filter type ISU_LCL_5R7 and -6R7

• Disconnect the wire plug. (1)

• Remove the two screws holding the fan unit. (2)
• Pull the fan unit out. (3)
• Install new fan in reverse order.
2 2
Maintenance
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LCL filter type ALCL-1x and -2x

The life span of the cooling fans is about 60 000 hours. The actual life span depends
on the running time of the fan, ambient temperature and dust concentration.
Replacements are available from ABB. Do not use other than ABB specified spare
parts.
Procedure

• Disconnect the fan wiring plug (1).

• Remove the screws of the fan fastening rail/clip (2).
• Pull the fan out (3).
Install a new fan in reverse order.
ALCL-1x ALCL-2x
2 2
1
3
Maintenance
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Replacing the supply module, frame size R7i
WARNING! The module is heavy. Do not lift it alone.

Removing the module

• Open the door of the supply module cabinet.
• Remove the shrouds in front of the IGBT module. Remove also the brackets
where they prevent the module from being pulled out.(1)
• Disconnect the fibre optic cables from the module. (2)
• Remove the air baffle plate form the module.(3)
• Remove the fan. See Replacing the cooling fans, page 44. (4)
• Disconnect the AC cables from the module busbars.(5)
• Remove the screws that fasten the module to the cabinet at top and bottom.(6)
• Loosen the two DC busbar bolts.(7) Do not remove: The bolt or nut may slip and
fall inside the module.
• Pull the module out of the cabinet.
Install a new module in reverse order.
Maintenance
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5
4
Maintenance
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Replacing the supply module, frame size R8i
WARNING! The IGBT supply modules are heavy and have a high centre of gravity.
Be careful when manoeuvring the modules. In order to minimise the danger of
toppling over, keep the support legs of the modules extended whenever
manoeuvring outside the cabinet.
Removing the module

• Open the door of the supply module cabinet.

• Remove the shroud covering the upper part of the cabinet.
• Open the transparent cover on the front of the module and disconnect the fibre
optic cables. Move the cables aside. (1)
• Remove the L-shaped DC busbars on top of the module. (2)
• Disconnect the socket terminal block (next to the DC busbars or at the upper part
of the module). (3)
• Remove the two module fastening screws (4a) at the top. At the base of the
module, loosen the two fastening screws (4b) but leave them in place; lift the
bracket (4c) to up position and lock it with two screws (4d).
• Insert the module pull-out ramp under the two screws at the base of the module
and tighten. (5)
• Pull the module carefully out of the cabinet along the ramp. Make sure the wires
do not catch. (6)
• Extend the support legs of the module. Keep the legs extended until the module is
about to be inserted back into the cabinet. (7)
Maintenance
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4a
2
1
6
7a 7b 4c
4d
4b
Inserting the module

• Move the module close to the ramp, then retract the support legs of the module.
• Push the module back into the cabinet – mind your fingers.
• Refasten the module fixing screws at the top, reconnect the DC busbars.
• Reconnect the cables (socket terminal block, fibre optic cables).
• Loosen the module fastening screws at the base of the module and remove the
pull-out ramp. Flip the module fastening bracket into the down position and
tighten the screws.
• Replace the shroud covering the upper part of the cabinet.
• Close the doors.
Maintenance
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LEDs
This table describes LEDs of the IGBT supply unit that are visible to the user.
Where LED When the LED is lit
RMIO board Red IGBT supply unit in fault state

Green The power supply on the board is OK.
Control panel mounting Red IGBT supply unit in fault state
platform
Green The main 24 VDC power supply for the control panel
and the RMIO board is OK.
APBU board (only in TXD (yellow) APBU is sending data.
supply units with parallel
RXD (yellow) APBU is receiving data.
connected modules)
PWR (green) 5 V internal voltage ok
BAT (green) Backup battery is switched on and the voltage is ok
(>2.8 V). See switch S3 on the APBU.
Redundancy (Reduced run capability)

If one of the parallel-connected IGBT supply modules must be taken out of the
cabinet for service, it is possible to continue operation using the remaining modules
at reduced power. For the description of the function, program settings and
instructions on the procedure on how to prepare the drive for running at reduced
power, see ACS800 IGBT Supply Unit Control Program Firmware Manual
(3AFE68315735 [English]).
Maintenance
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This chapter contains the technical data for the ACS800-207, the cabinet-installed
IGBT supply units.
Ratings
IGBT Supply Unit Basic Module Frame Nominal ratings (no overload use) Light overload use Heavy-duty use
ACS800-104… Icontmax Icont.max Imax SN Pcont.max In PN Ihd Phd
A (AC) A (DC) A (DC) kVA kW (DC) A (DC) kW A (DC) kW
UN=400 V (Range 380-415 V)
ACS800-207-0135-3 -0145-3 R7i 182 221 330 131 130 212 124 165 97
ACS800-207-0155-3 -0175-3 R7i 224 272 406 161 159 261 153 203 119
ACS800-207-0200-3 -0260-3+E205 R8i 284 344 471 204 202 331 194 258 151
ACS800-207-0260-3 -0320-3+E205 R8i 378 458 627 272 269 440 258 343 201
ACS800-207-0330-3 -0390-3+E205 R8i 473 573 784 340 336 550 323 429 252
ACS800-207-0440-3 -0510-3+E205 R8i 630 764 1046 453 448 733 430 571 335
ACS800-207-0660-3 -0390-3+E205 2×R8i 945 1146 1568 679 672 1100 646 857 503
ACS800-207-0860-3 -0510-3+E205 2×R8i 1235 1497 2049 888 879 1437 844 1120 657
ACS800-207-1270-3 -0510-3+E205 3×R8i 1833 2223 3042 1318 1304 2134 1252 1662 976
ACS800-207-1680-3 -0510-3+E205 4×R8i 2419 2933 4015 1739 1722 2816 1653 2194 1288
ACS800-207-2490-3 -0510-3+E205 6×R8i 3591 4354 5960 2581 2555 4180 2453 3257 1911
UN=500 V (Range 380-500 V)
ACS800-207-0165-5 -0175-5 R7i 180 218 327 156 154 210 148 163 115
ACS800-207-0195-5 -0215-5 R7i 220 267 399 191 189 256 181 200 141
ACS800-207-0230-5 -0320-5+E205 R8i 270 327 475 234 231 314 222 245 173
ACS800-207-0310-5 -0400-5+E205 R8i 360 436 633 312 309 419 296 327 231
ACS800-207-0390-5 -0460-5+E205 R8i 450 546 792 390 386 524 370 408 289
ACS800-207-0520-5 -0610-5+E205 R8i 600 727 1056 520 514 698 494 544 385
ACS800-207-0780-5 -0460-5+E205 2×R8i 900 1091 1584 779 772 1048 741 816 577
ACS800-207-1020-5 -0610-5+E205 2×R8i 1176 1426 2069 1018 1008 1369 968 1067 754
ACS800-207-1510-5 -0610-5+E205 3×R8i 1746 2117 3072 1512 1497 2032 1437 1584 1120
ACS800-207-2000-5 -0610-5+E205 4×R8i 2304 2794 4054 1995 1975 2682 1896 2090 1478
ACS800-207-2960-5 -0610-5+E205 6×R8i 3420 4147 6017 2962 2932 3981 2815 3102 2193
UN=690 V (Range 525-690 V)
ACS800-207-0155-7 -0175-7 R7i 119 144 216 142 141 139 135 108 105
ACS800-207-0175-7 -0215-7 R7i 135 164 245 161 160 157 153 122 119
ACS800-207-0220-7 -0260-7+E205 R8i 180 218 327 215 213 210 204 163 159
ACS800-207-0300-7 -0400-7+E205 R8i 250 303 453 299 296 291 284 227 221
ACS800-207-0360-7 -0440-7+E205 R8i 300 364 544 359 355 349 341 272 266
ACS800-207-0480-7 -0580-7+E205 R8i 400 485 726 478 473 466 454 363 354
ACS800-207-0720-7 -0440-7+E205 2×R8i 600 727 1088 717 710 698 682 544 531
ACS800-207-0940-7 -0580-7+E205 2×R8i 784 951 1422 937 928 913 890 711 694
ACS800-207-1390-7 -0580-7+E205 3×R8i 1164 1411 2111 1391 1377 1355 1322 1056 1030
ACS800-207-1840-7 -0580-7+E205 4×R8i 1536 1862 2786 1836 1817 1788 1745 1393 1359
ACS800-207-2730-7 -0580-7+E205 6×R8i 2280 2764 4136 2725 2698 2654 2590 2068 2018
ACS800-207-3630-7 -0580-7+E205 8×R8i 3040 3686 5514 3633 3597 3539 3453 2757 2690
ACS800-207-4550-7 -0580-7+E205 10×R8i 3800 4607 6893 4541 4496 4423 4316 3446 3363
ACS800-207-5450-7 -0580-7+E205 12×R8i 4560 5529 8271 5450 5395 5308 5179 4136 4036
00184674.xls / G
Nominal ratings
Icont.max continuous rms input (AC) or output (DC) current. No overload capability at 40°C.
Imax maximum output current. Available for 10 s at start, otherwise as long as allowed by module temperature.
Pcont.max nominal output power

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Light overload use (10% overload capability) ratings

IN continuous rms current. 10% overload is allowed for one minute every 5 minutes.
PN output power in light overload use
Heavy-duty use (50% overload capability) ratings
Ihd continuous rms current. 50% overload is allowed for one minute every 5 minutes.
Phd output power in heavy duty-use
Dimensions, weight, noise, losses, air flow

1)
Type Height Width Weight Depth Noise Noise Power Efficiency Air flow
level level loss
mm mm kg mm dB (DOL) dB kW % m3/h
UN=400 V (Range 380-415 V)
ACS800-207-0135-3 2130 1000 350 600 74 - 1.9 97% 1300
ACS800-207-0155-3 2130 1000 350 600 74 - 2.1 97% 1300
ACS800-207-0200-3 2130 1400 1340 644 74 57 5.9 97% 1880
ACS800-207-0260-3 2130 1400 1340 644 74 57 8.0 97% 1880
ACS800-207-0330-3 2130 1400 1340 644 74 57 10.3 97% 1880
ACS800-207-0440-3 2130 1400 1340 644 74 57 14.6 97% 1880
ACS800-207-0660-3 2130 2000 1750 644 76 59 20.5 97% 3840
ACS800-207-0860-3 2130 2000 1750 644 76 59 28.3 97% 3840
ACS800-207-1270-3 2130 2600 2400 644 78 61 41.7 97% 6400
ACS800-207-1680-3 2130 2800 2580 644 78 61 54.8 97% 7680
ACS800-207-2490-3 2130 4000 3600 644 80 63 80.9 97% 11520
UN=500 V (Range 380-500 V)
ACS800-207-0165-5 2130 1000 350 600 74 - 2.0 97% 1300
ACS800-207-0195-5 2130 1000 350 600 74 - 2.2 97% 1300
ACS800-207-0230-5 2130 1400 1340 644 74 57 6.2 97% 1880
ACS800-207-0310-5 2130 1400 1340 644 74 57 8.4 97% 1880
ACS800-207-0390-5 2130 1400 1340 644 74 57 10.6 97% 1880
ACS800-207-0520-5 2130 1400 1340 644 74 57 14.9 97% 1880
ACS800-207-0780-5 2130 2000 1750 644 76 59 21.2 97% 3840
ACS800-207-1020-5 2130 2000 1750 644 76 59 28.9 97% 3840
ACS800-207-1510-5 2130 2600 2400 644 78 61 42.7 97% 6400
ACS800-207-2000-5 2130 2800 2580 644 78 61 56.1 97% 7680
ACS800-207-2960-5 2130 4000 3600 644 80 63 82.9 97% 11520
UN=690 V (Range 525-690 V)
ACS800-207-0165-5 2130 1000 350 600 74 - 2.0 97% 1300
ACS800-207-0195-5 2130 1000 350 600 74 - 2.2 97% 1300
ACS800-207-0220-7 2130 1400 1340 644 74 57 8.3 96% 1880
ACS800-207-0300-7 2130 1400 1340 644 74 57 9.4 97% 1880
ACS800-207-0360-7 2130 1400 1340 644 74 57 13.3 96% 1880
ACS800-207-0480-7 2130 1400 1340 644 74 57 14.6 97% 1880
ACS800-207-0720-7 2130 2000 1750 644 76 59 26.6 96% 3840
ACS800-207-0940-7 2130 2000 1750 644 76 59 28.5 97% 3840
ACS800-207-1390-7 2130 2600 2400 644 78 61 42.3 97% 6400
ACS800-207-1840-7 2130 2800 2580 644 78 61 55.7 97% 7680
ACS800-207-2730-7 2130 3600 3400 644 80 63 82.5 97% 11520
ACS800-207-3630-7 2130 4400 4250 644 81 64 110.1 97% 15360
ACS800-207-4550-7 2130 5600 5280 644 81 64 137.7 97% 19200
ACS800-207-5450-7 2130 6400 6100 644 81 64 165.1 97% 23040
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1) Depthfor a standard unit. When the cooling air inlet is through the cabinet bottom, the depth
increases 120-130 mm depending on the unit. For details on the cooling air intake from below, see
ACS800 Multidrive Mechanical Installation (3AFE68233402 [English]).

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Air inlet and outlet filter type

Degree of protection Inlet Outlet
IP22, IP42, IP22R, IP42R Luftfilter / airTex G150 -
IP54, IP54R Luftfilter / airComp 300-50 Luftfilter / airTex G150
See www.luftfilter.com.
Input power cable lead-through size and terminal sizes
Supply unit equipped with R7i module

Busbar dimensions No. of Bolt size Tightening Cable lead-
busbars torque through
3 (one per M12 70 Nm 3 × 60 mm

phase) (½”) (50 lb.ft) (6 × 2.36“)
Supply unit equipped with R8i module(s)

Busbar dimensions No. of Bolt size Tightening Cable lead-
busbars 2) torque through 1)
13 [0.51] 40 [1.57]
M12 70 Nm n × 60 mm
2)
(½”) (50 lb.ft) (n × 2.36“)
50 [1.97]
1) n = 9 for units with one to two parallel IGBT supply modules, n = 18 for units with three to four parallel
modules, n = 27 for units with five to six parallel modules, etc.

2) No.
of input busbars:
No. of busbars per connection point

No. of supply modules
L1 L2 L3
1 1 1 1
2 2 2 2

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No. of busbars per connection point

No. of supply modules
L1 L2 L3
3 3 3 3
4 3 3 3
5 3 3 3
Degree of protection
IP21, IP22, IP42, IP54, IP22R, IP42R, IP54R (with air duct outlet) and UL approved
NEMA 1 and NEMA 12.
Materials
Cabinet Hot-dip zinc-coated (thickness approx. 20 µm) sheet steel with polyester thermosetting powder
coating (thickness approx. 80 µm) on visible surfaces. Colour: RAL 7035 (light beige, semigloss).
Busbars Tin- or silver-plated copper
Fire safety Insulating materials and non-metallic items mostly self-extinctive.

(IEC 60332-1)
Packaging Frame of wood or plywood with PE-LD wrapping and PP or steel bands.
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 will be 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.
Standards and markings

See ACS800 Multidrive and ACS800 Multidrive Modules Planning the Electrical
Installation [3AFE64783742 (English)].
Other data
The following subsections in chapter Technical data - ACS800-104 IGBT supply
module are also valid for ACS800-207:
• Derating
• LCL filter types
• AC and DC fuses
• Input power connection
• Ambient conditions
• RMIO board specifications

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This chapter contains the technical data for ACS800-104 IGBT supply modules.
Type equivalence table

Module name 1) Module type 2) Cabinet-installed unit 3)
400V
ACS800-204-0135-3 ACS800-104-0145-3 ACS800-207-0135-3
ACS800-204-0155-3 ACS800-104-0175-3 ACS800-207-0155-3
ACS800-204-0200-3 ACS800-104-0260-3 ACS800-207-0200-3
ACS800-204-0260-3 ACS800-104-0320-3 ACS800-207-0260-3
ACS800-204-0330-3 ACS800-104-0390-3 ACS800-207-0330-3
ACS800-204-0440-3 ACS800-104-0510-3 ACS800-207-0440-3
ACS800-204-0660-3 ACS800-104-0770-3 ACS800-207-0660-3
ACS800-204-0860-3 ACS800-104-1030-3 ACS800-207-0860-3
ACS800-204-1270-3 ACS800-104-1540-3 ACS800-207-1270-3
ACS800-204-1680-3 ACS800-104-2050-3 ACS800-207-1680-3
500V
ACS800-204-0165-5 ACS800-104-0175-5 ACS800-207-0165-5
ACS800-204-0195-5 ACS800-104-0215-5 ACS800-207-0195-5
ACS800-204-0230-5 ACS800-104-0320-5 ACS800-207-0230-5
ACS800-204-0310-5 ACS800-104-0400-5 ACS800-207-0310-5
ACS800-204-0390-5 ACS800-104-0460-5 ACS800-207-0390-5
ACS800-204-0520-5 ACS800-104-0610-5 ACS800-207-0520-5
ACS800-204-0780-5 ACS800-104-0910-5 ACS800-207-0780-5
ACS800-204-1020-5 ACS800-104-1210-5 ACS800-207-1020-5
ACS800-204-1510-5 ACS800-104-1820-5 ACS800-207-1510-5
ACS800-204-2000-5 ACS800-104-2430-5 ACS800-207-2000-5
690V
ACS800-204-0155-7 ACS800-104-0175-7 ACS800-207-0155-7
ACS800-204-0175-7 ACS800-104-0215-7 ACS800-207-0175-7
ACS800-204-0220-7 ACS800-104-0320-7 ACS800-207-0220-7
ACS800-204-0300-7 ACS800-104-0400-7 ACS800-207-0300-7
ACS800-204-0360-7 ACS800-104-0440-7 ACS800-207-0360-7
ACS800-204-0480-7 ACS800-104-0580-7 ACS800-207-0480-7
ACS800-204-0720-7 ACS800-104-0870-7 ACS800-207-0720-7
ACS800-204-0940-7 ACS800-104-1160-7 ACS800-207-0940-7
ACS800-204-1390-7 ACS800-104-1740-7 ACS800-207-1390-7
ACS800-204-1840-7 ACS800-104-2320-7 ACS800-207-1840-7
1)
Module name used in sales tools, brochures etc.
2)
Module type code printed on type designation label which attached to module.
3) Type of the corresponding cabinet-installed supply unit (ACS800 Multidrive).

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Ratings
Nominal ratings (no overload use) Light overload use Heavy-duty use
Basic module Frame
Module type Icontmax Icont.max Imax SN Pcont.max In PN Ihd Phd
ACS800-104…
A (AC) A (DC) A (DC) kVA kW (DC) A (DC) kW A (DC) kW
400 V
ACS800-104-0145-3 -0145-3 R7i 182 221 330 131 130 212 124 165 97
ACS800-104-0175-3 -0175-3 R7i 224 272 406 161 159 261 153 203 119
ACS800-104-0260-3+E205 -0260-3+E205 R8i 284 344 471 204 202 331 194 258 151
ACS800-104-0320-3+E205 -0320-3+E205 R8i 378 458 627 272 269 440 258 343 201
ACS800-104-0390-3+E205 -0390-3+E205 R8i 473 573 784 340 336 550 323 429 252
ACS800-104-0510-3+E205 -0510-3+E205 R8i 630 764 1046 453 448 733 430 571 335
ACS800-104-0770-3+E205 -0390-3+E205 2×R8i 945 1146 1568 679 672 1100 646 857 503
ACS800-104-1030-3+E205 -0510-3+E205 2×R8i 1235 1497 2049 888 879 1437 844 1120 657
ACS800-104-1540-3+E205 -0510-3+E205 3×R8i 1833 2223 3042 1318 1304 2134 1252 1662 976
ACS800-104-2050-3+E205 -0510-3+E205 4×R8i 2419 2933 4015 1739 1722 2816 1653 2194 1288
500 V
ACS800-104-0175-5 -0175-5 R7i 180 218 327 156 154 210 148 163 115
ACS800-104-0215-5 -0215-5 R7i 220 267 399 191 189 256 181 200 141
ACS800-104-0320-5+E205 -0320-5+E205 R8i 270 327 475 234 231 314 222 245 173
ACS800-104-0400-5+E205 -0400-5+E205 R8i 360 436 633 312 309 419 296 327 231
ACS800-104-0460-5+E205 -0460-5+E205 R8i 450 546 792 390 386 524 370 408 289
ACS800-104-0610-5+E205 -0610-5+E205 R8i 600 727 1056 520 514 698 494 544 385
ACS800-104-0910-5+E205 -0460-5+E205 2×R8i 900 1091 1584 779 772 1048 741 816 577
ACS800-104-1210-5+E205 -0610-5+E205 2×R8i 1176 1426 2069 1018 1008 1369 968 1067 754
ACS800-104-1820-5+E205 -0610-5+E205 3×R8i 1746 2117 3072 1512 1497 2032 1437 1584 1120
ACS800-104-2430-5+E205 -0610-5+E205 4×R8i 2304 2794 4054 1995 1975 2682 1896 2090 1478
690 V
ACS800-104-0175-7 -0175-7 R7i 119 144 216 142 141 139 135 108 105
ACS800-104-0215-7 -0215-7 R7i 135 164 245 161 160 157 153 122 119
ACS800-104-0260-7+E205 -0260-7+E205 R8i 180 218 327 215 213 210 204 163 159
ACS800-104-0400-7+E205 -0400-7+E205 R8i 250 303 453 299 296 291 284 227 221
ACS800-104-0440-7+E205 -0440-7+E205 R8i 300 364 544 359 355 349 341 272 266
ACS800-104-0580-7+E205 -0580-7+E205 R8i 400 485 726 478 473 466 454 363 354
ACS800-104-0870-7+E205 -0440-7+E205 2×R8i 600 727 1088 717 710 698 682 544 531
ACS800-104-1160-7+E205 -0580-7+E205 2×R8i 784 951 1422 937 928 913 890 711 694
ACS800-104-1740-7+E205 -0580-7+E205 3×R8i 1164 1411 2111 1391 1377 1355 1322 1056 1030
ACS800-104-2320-7+E205 -0580-7+E205 4×R8i 1536 1862 2786 1836 1817 1788 1745 1393 1359
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Nominal ratings
Icont.max continuous rms input (AC) or output (DC) current. No overload capability at 40°C.
Imax maximum output current. Available for 10 s at start, otherwise as long as allowed by module temperature.
Pcont.max nominal output power
Light overload use (10% overload capability) ratings
IN continuous rms current. 10% overload is allowed for one minute every 5 minutes.
PN output power in light overload use
Heavy-duty use (50% overload capability) ratings
Ihd continuous rms current. 50% overload is allowed for one minute every 5 minutes.
Phd output power in heavy duty-use
Derating
The load capacity (current and power) decreases if the installation site altitude exceeds 1000 metres
(3300 ft), or if the ambient temperature exceeds 40 °C (104 °F).
Temperature derating
In the temperature range +40°C (+104°F) to +50 °C (+122°F) the rated output current is decreased 1 %
for every additional 1 °C (1.8°F). The output current is calculated by multiplying the current given in the
rating table by the derating factor.
Example If the ambient temperature is +50°C (+122°F), the derating factor is 100% - 1 % · 10°C =
90 % or 0.90. The output current is then 0.90 · I or 0.90 · I . °C
N hd
Note: Icont.max rating is not allowed above 40°C (104°F).

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

Module type Frame LCL filter type
400 V
ACS800-104-0145-3 R7i ALCL-04-5
ACS800-104-0175-3 R7i ALCL-05-5
ACS800-104-0260-3+E205 R8i ALCL-12-5
ACS800-104-0320-3+E205 R8i ALCL-13-5
ACS800-104-0390-3+E205 R8i ALCL-14-5
ACS800-104-0510-3+E205 R8i ALCL-15-5
ACS800-104-0770-3+E205 2×R8i ALCL-24-5
ACS800-104-1030-3+E205 2×R8i ALCL-25-5
ACS800-104-1540-3+E205 3×R8i 2×ALCL-24-5
ACS800-104-2050-3+E205 4×R8i 2×ALCL-25-5
500 V
ACS800-104-0175-5 R7i ALCL-04-5
ACS800-104-0215-5 R7i ALCL-05-5
ACS800-104-0320-5+E205 R8i ALCL-12-5
ACS800-104-0400-5+E205 R8i ALCL-13-5
ACS800-104-0460-5+E205 R8i ALCL-14-5
ACS800-104-0610-5+E205 R8i ALCL-15-5
ACS800-104-0910-5+E205 2×R8i ALCL-24-5
ACS800-104-1210-5+E205 2×R8i ALCL-25-5
ACS800-104-1820-5+E205 3×R8i 2×ALCL-24-5
ACS800-104-2430-5+E205 4×R8i 2×ALCL-25-5
690 V
ACS800-104-0175-7 R7i ALCL-04-7
ACS800-104-0215-7 R7i ALCL-05-7
ACS800-104-0260-7+E205 R8i ALCL-12-7
ACS800-104-0400-7+E205 R8i ALCL-13-7
ACS800-104-0440-7+E205 R8i ALCL-14-7
ACS800-104-0580-7+E205 R8i ALCL-15-7
ACS800-104-0870-7+E205 2×R8i ALCL-24-7
ACS800-104-1160-7+E205 2×R8i ALCL-25-7
ACS800-104-1740-7+E205 3×R8i 2×ALCL-24-7
ACS800-104-2320-7+E205 4×R8i 2×ALCL-25-7
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AC and DC fuses
Note 1: Larger fuses must not be used.
Note 2: Fuses from other manufacturers can be used if they meet the ratings.
Note 3: The recommended fuses are for branch circuit protection per NEC as
required for the UL approval.
Module type DC fuse information AC fuse information
Bussman type Qty Bussman type In Qty
400 V
ACS800-104-0145-3 170M3819 2 170M3817 315 3
ACS800-104-0175-3 170M6810 2 170M5808 400 3
ACS800-104-0260-3 170M6810 2 170M5809 450 3
ACS800-104-0320-3 170M8545 2 170M6810 630 3
ACS800-104-0390-3 170M8552 2 170M8545 800 3
ACS800-104-0510-3 170M8547 2 170M6814 1000 3
ACS800-104-0770-3 170M8552 4 170M6419 1600 3
ACS800-104-1030-3 170M8547 4 170M6421 2000 3
ACS800-104-1540-3 170M8547 6 170M6419 1600 6
ACS800-104-2050-3 170M8547 8 170M6421 2000 6
500 V
ACS800-104-0175-5 170M3819 2 170M3817 315 3
ACS800-104-0215-5 170M6810 2 170M5808 400 3
ACS800-104-0320-5 170M6810 2 170M5809 450 3
ACS800-104-0400-5 170M8545 2 170M6810 630 3
ACS800-104-0460-5 170M8552 2 170M8545 800 3
ACS800-104-0610-5 170M8547 2 170M6814 1000 3
ACS800-104-0910-5 170M8552 4 170M6419 1600 3
ACS800-104-1210-5 170M8547 4 170M6421 2000 3
ACS800-104-1820-5 170M8547 6 170M6419 1600 6
ACS800-104-2430-5 170M8547 8 170M6421 2000 6
690 V
ACS800-104-0175-5 170M6301 2 170M3816 250 3
ACS800-104-0215-5 170M6303 2 170M3817 315 3
ACS800-104-0260-7 170M8643 2 170M3817 315 3
ACS800-104-0400-7 170M8645 2 170M5809 450 3
ACS800-104-0440-7 170M8646 2 170M5809 450 3
ACS800-104-0580-7 170M8647 2 170M6810 630 3
ACS800-104-0870-7 170M8646 4 170M6414 1000 3
ACS800-104-1160-7 170M8647 4 170M6416 1250 3
ACS800-104-1740-7 170M8647 6 170M6414 1000 6
ACS800-104-2320-7 170M8647 8 170M6416 1250 6
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IGBT supply module capacitance, dimensions and noise

Capacitance Height Width Depth Weight Noise 1)
Module type Frame
microF mm (in.) mm (in.) mm (in.) kg (lbs) dBA
400 V
ACS800-104-0145-3 R7i 6150 966 (38.03) 170 (6.69) 408 (16.06) 37 (82) 74
ACS800-104-0175-3 R7i 6150 966 (38.03) 170 (6.69) 408 (16.06) 37 (82) 74
ACS800-104-0260-3+E205 1×R8i 8200 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 74
ACS800-104-0320-3+E205 1×R8i 10250 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 74
ACS800-104-0390-3+E205 1×R8i 12300 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 74
ACS800-104-0510-3+E205 1×R8i 14350 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 76
ACS800-104-0770-3+E205 2) 2×R8i 24600 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 76
ACS800-104-1030-3+E205 2) 2×R8i 28700 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 78
ACS800-104-1540-3+E205 2) 3×R8i 43050 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 78
ACS800-104-2050-3+E205 2) 4×R8i 57400 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 80
500 V
ACS800-104-0175-5 R7i 6150 966 (38.03) 170 (6.69) 408 (16.06) 37 (82) 74
ACS800-104-0215-5 R7i 6150 966 (38.03) 170 (6.69) 408 (16.06) 37 (82) 74
ACS800-104-0320-5+E205 1×R8i 8200 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 74
ACS800-104-0400-5+E205 1×R8i 10250 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 74
ACS800-104-0460-5+E205 1×R8i 12300 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 74
ACS800-104-0610-5+E205 1×R8i 14350 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 76
ACS800-104-0910-5+E205 2) 2×R8i 24600 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 76
ACS800-104-1210-5+E205 2) 2×R8i 28700 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 78
ACS800-104-1820-5+E205 2) 3×R8i 43050 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 78
ACS800-104-2430-5+E205 2) 4×R8i 57400 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 80
690 V
ACS800-104-0175-7 R7i 3070 966 (38.03) 170 (6.69) 408 (16.06) 37 (82) 74
ACS800-104-0215-7 R7i 3070 966 (38.03) 170 (6.69) 408 (16.06) 37 (82) 74
ACS800-104-0260-7+E205 1×R8i 4600 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 74
ACS800-104-0400-7+E205 1×R8i 6130 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 74
ACS800-104-0440-7+E205 1×R8i 6130 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 74
ACS800-104-0580-7+E205 1×R8i 7670 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 76
ACS800-104-0870-7+E205 2×R8i 9200 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 76
ACS800-104-1160-7+E205 2) 2×R8i 15330 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 78
ACS800-104-1740-7+E205 2) 3×R8i 18400 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 78
ACS800-104-2320-7+E205 2) 4×R8i 27600 1397 (55.00) 245 (9.65) 596 (23.46) 150 (330) 80
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1)
Noise for the complete IGBT supply unit including the LCL filter(s)
2) Dimensions for single module only.

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LCL filter dimensions, weight and air flow

Height Width Depth Weight Air flow
LCL filter type
mm (in.) mm (in.) mm (in.) kg (lbs) m3/h (ft3/min)
ALCL-04-5 845 (33.27) 377.8 (13.30) 304.5 (11.99) 100 (220.46) 300 (176.57)
ALCL-05-5 845 (33.27) 377.8 (13.30) 304.5 (11.99) 100 (220.46) 300 (176.57)
ALCL-04-7 845 (33.27) 377.8 (13.30) 304.5 (11.99) 100 (220.46) 300 (176.57)
ALCL-05-7 845 (33.27) 377.8 (13.30) 304.5 (11.99) 100 (220.46) 300 (176.57)
ALCL_1X_XX 1397 (55.00) 240 (9.45) 499 (9.45) 180 (396.86) 400 (235.43)
ALCL_2X_XX 1397 (55.00) 240 (9.45) 573 (22.56) 305 (672.41) 1280 (753.38)
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Power losses: IGBT supply module and LCL filter

Module type Supply module LCL filter Total
kW Btu/h kW Btu/h kW Btu/h
400 V
ACS800-104-0145-3 1.90 6489 1.90 6489 3.80 12978
ACS800-104-0175-3 2.10 7172 2.10 7172 4.20 14344
ACS800-104-0260-3+E205 3.70 12636 2.20 7513 5.90 20150
ACS800-104-0320-3+E205 4.90 16734 3.10 10587 8.00 27321
ACS800-104-0390-3+E205 6.10 20833 3.90 13319 10.00 34152
ACS800-104-0510-3+E205 8.00 27321 7.00 23906 15.00 51228
ACS800-104-0770-3+E205 11.80 40299 9.20 31420 21.00 71719
ACS800-104-1030-3+E205 15.40 52594 12.60 43031 28.00 95625
ACS800-104-1540-3+E205 22.80 77866 19.20 65571 42.00 143438
ACS800-104-2050-3+E205 29.90 102114 25.10 85721 55.00 187835
500 V
ACS800-104-0175-5 2.00 6830 2.00 6830 4.00 13661
ACS800-104-0215-5 2.20 7513 2.00 6830 4.40 15027
ACS800-104-0320-5+E205 4.00 13661 2.20 7513 6.20 21174
ACS800-104-0400-5+E205 5.40 18442 3.00 10246 8.40 28688
ACS800-104-0460-5+E205 5.90 20150 5.10 17417 11.00 37567
ACS800-104-0610-5+E205 7.80 26638 7.20 24589 15.00 51228
ACS800-104-0910-5+E205 11.90 40641 9.10 31078 21.00 71719
ACS800-104-1210-5+E205 15.10 51569 13.90 47471 29.00 99040
ACS800-104-1820-5+E205 22.30 76158 20.70 70694 43.00 146853
ACS800-104-2430-5+E205 29.30 100065 26.70 91185 56.00 191250
690 V
ACS800-104-0175-7 2.20 7500 2.30 7855 4.30 14685
ACS800-104-0215-7 2.60 8900 2.60 8879 5.20 17759
ACS800-104-0260-7+E205 4.80 16393 3.50 11953 8.30 28346
ACS800-104-0400-7+E205 6.10 20833 3.30 11270 9.40 32103
ACS800-104-0440-7+E205 7.00 23906 6.00 20491 13.00 44397
ACS800-104-0580-7+E205 7.50 25614 7.50 25614 15.00 51228
ACS800-104-0870-7+E205 13.30 45422 13.70 46788 27.00 92210
ACS800-104-1160-7+E205 14.60 49862 14.40 49179 29.00 99040
ACS800-104-1740-7+E205 21.70 74109 20.30 69328 42.00 143438
ACS800-104-2320-7+E205 28.50 97333 27.50 93917 56.00 191250

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IGBT supply unit cooling characteristics

See the dimensional drawings for free space requirements.
Minimum effective area of air Minimum effective area of air Max. pressure
inlet 2) outlet 2) drop of
Nominal air
IGBT supply Frame cabinet at
flow 1) with Luftfilter/ with Luftfilter/
module type size unfiltered unfiltered nominal air
airTex G150 airTex G150
flow 2)
m3/h (ft3/min) cm2 (in2) cm2 (in2) cm2 (in2) cm2 (in2) Pa
400 V
ACS800-104-0145-3 R7i 800 (470) 960 (150) 1920 (295) 1536 (240) 3072 (475) 150
ACS800-104-0175-3 R7i 800 (470) 960 (150) 1920 (295) 1536 (240) 3072 (475) 150
ACS800-104-0260-3 1×R8i 1280 (750) 960 (150) 1920 (295) 1536 (240) 3072 (475) 150
ACS800-104-0320-3 1×R8i 1280 (750) 960 (150) 1920 (295) 1536 (240) 3072 (475) 150
ACS800-104-0390-3 1×R8i 1280 (750) 960 (150) 1920 (295) 1536 (240) 3072 (475) 150
ACS800-104-0510-3 1×R8i 1280 (750) 960 (150) 1920 (295) 1536 (240) 3072 (475) 150
ACS800-104-0770-3 2×R8i 2560 (1510) 1440 (225) 2280 (355) 2304 (355) 4608 (715) 180
ACS800-104-1030-3 2×R8i 2560 (1510) 1440 (225) 2280 (355) 2304 (355) 4608 (715) 180
ACS800-104-1540-3 3×R8i 3840 (2260) 1920 (295) 3840 (595) 3072 (475) 6144 (950) 180
ACS800-104-2050-3 4×R8i 5120 (3010) 2880 (445) 5700 (885) 4608 (715) 9216 (1430) 180
500 V
ACS800-104-0175-5 R7i 800 (470) 960 (150) 1920 (295) 1536 (240) 3072 (475) 150
ACS800-104-0215-5 R7i 800 (470) 960 (150) 1920 (295) 1536 (240) 3072 (475) 150
ACS800-104-0320-5 1×R8i 1280 (750) 960 (150) 1920 (295) 1536 (240) 3072 (475) 150
ACS800-104-0400-5 1×R8i 1280 (750) 960 (150) 1920 (295) 1536 (240) 3072 (475) 150
ACS800-104-0460-5 1×R8i 1280 (750) 960 (150) 1920 (295) 1536 (240) 3072 (475) 150
ACS800-104-0610-5 1×R8i 1280 (750) 960 (150) 1920 (295) 1536 (240) 3072 (475) 150
ACS800-104-0910-5 2×R8i 2560 (1510) 1440 (225) 2280 (355) 2304 (355) 4608 (715) 180
ACS800-104-1210-5 2×R8i 2560 (1510) 1440 (225) 2280 (355) 2304 (355) 4608 (715) 180
ACS800-104-1820-5 3×R8i 3840 (2260) 1920 (295) 3840 (595) 3072 (475) 6144 (950) 180
ACS800-104-2430-5 4×R8i 5120 (3010) 2880 (445) 5700 (885) 4608 (715) 9216 (1430) 180
690 V
ACS800-104-0175-7 R7i 800 (470) 960 (150) 1920 (295) 1536 (240) 3072 (475) 150
ACS800-104-0215-7 R7i 800 (470) 960 (150) 1920 (295) 1536 (240) 3072 (475) 150
ACS800-104-0260-7 1×R8i 1280 (750) 960 (150) 1920 (295) 1536 (240) 3072 (475) 150
ACS800-104-0320-7 1×R8i 1280 (750) 960 (150) 1920 (295) 1536 (240) 3072 (475) 150
ACS800-104-0400-7 1×R8i 1280 (750) 960 (150) 1920 (295) 1536 (240) 3072 (475) 150
ACS800-104-0440-7 1×R8i 1280 (750) 960 (150) 1920 (295) 1536 (240) 3072 (475) 150
ACS800-104-0580-7 1×R8i 1280 (750) 960 (150) 1920 (295) 1536 (240) 3072 (475) 180
ACS800-104-0870-7 2×R8i 2560 (1510) 1440 (225) 2280 (355) 2304 (355) 4608 (715) 180
ACS800-104-1160-7 2×R8i 2560 (1510) 1440 (225) 2280 (355) 2304 (355) 4608 (715) 180
ACS800-104-1740-7 3×R8i 3840 (2260) 1920 (295) 3840 (595) 3072 (475) 6144 (950) 180
ACS800-104-2320-7 4×R8i 5120 (3010) 2880 (445) 5700 (885) 4608 (715) 9216 (1430) 150
1) Valid for the converter module. For the LCL filter figures, see section LCL filter dimensions, weight and air flow.
2) Valid for the IGBT Supply Unit including converter module(s) and LCL filter(s).

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Cable terminals
DC and AC terminal sizes and tightening torques are given below.
Frame size DC terminals AC terminals
R7i
M12
M12 (busbars or cable to quick connector)
R8i Tightening torque: 50 Nm (37 lbf.ft)
Tightening torque: 50 Nm (37 lbf.ft)
Max. intrusion into module: 20 mm (0.8”).
Input power connection

Voltage 380/400/415 VAC 3-phase for 415 VAC units
380/400/415/440/460/480/500 VAC 3-phase for 500 VAC units
525/550/575/600/660/690 VAC 3-phase for 690 VAC units
±10% variation from converter nominal voltage is allowed as default.
Frequency 50 ± 2 Hz or 60 ± 2 Hz. Maximum rate of change 17%/s.
Prospective short-circuit 65 kA (Icf) for modules and cabinet-installed IGBT supply units without grounding switch.
current (IEC 60439-1) 50 kA (Icw) for cabinet-installed IGBT supply units with grounding switch.
US and Canada: The drive is suitable for use on a circuit capable of delivering not more
than 65,000 symmetrical amperes (rms) at 600 V maximum.
Imbalance Max. ± 3% of nominal phase-to-phase input voltage
Voltage Dips Max. 25%
Power Factor I1
· cos phii > 0.98
Irms
Cos phii = 1.00 (fundamental at nominal load)

I1 = fundamental input current rms value
Irms = total input current rms value

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Harmonic distortion Harmonics are below the limits defined in IEEE519.

Rsc THD Voltage [%] THD Current [%]
20 4 4
100 0.8 5
2
I 50
 In nth harmonic component
THD = ∑  n 
2  IN  IN nominal current
THD = Total Harmonic Distortion (THD). The voltage THD depends on the short-circuit
ratio (Rsc). The spectrum of the distortion also contains interharmonics.
Rsc = Isc/IN
Isc= short-circuit current at point of common coupling (PCC)
IN= IGBT supply unit nominal current
Output connection
Voltage 510…560 V DC for 400 V units
510…675 V DC for 500 V units
710…930 V DC for 690 V units
Switching frequency 3 kHz (average)
Degree of protection
IP00
Ambient conditions
The drive is to be used in a heated, indoor controlled environment.
Operation Storage Transportation
installed for stationary use in the protective package in the protective package
Installation site altitude 0 to 4000 m (13123 ft) above - -
sea level [above 1000 m
(3281 ft), see Derating on
page 58].
Air temperature 0 to +50°C (32 to 122°F). No -40 to +70°C (-40 to +158 °F) -40 to +70°C (-40 to +158 °F)
frost allowed. See Derating
on page 58.
Relative humidity 5 to 95% Max. 95% Max. 95%
No condensation allowed. Maximum allowed relative humidity is 60% in the presence of
corrosive gases.
Contamination levels No conductive dust allowed.
(IEC 60721-3-3, IEC 60721-3- Boards without coating: Boards without coating: Boards without coating:
2, IEC 60721-3-1) Chemical gases: Class 3C1 Chemical gases: Class 1C2 Chemical gases: Class 2C2
Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2
Boards with coating: Boards with coating: Boards with coating:
Chemical gases: Class 3C2 Chemical gases: Class 1C2 Chemical gases: Class 2C2
Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2
Atmospheric pressure 70 to 106 kPa 70 to 106 kPa 60 to 106 kPa
0.7 to 1.05 atmospheres 0.7 to 1.05 atmospheres 0.6 to 1.05 atmospheres

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Vibration (IEC 60068-2) Max. 1 mm (0.04 in.) Max. 1 mm (0.04 in.) Max. 3.5 mm (0.14 in.)
(5 to 13.2 Hz), (5 to 13.2 Hz), (2 to 9 Hz),
max. 7 m/s2 (23 ft/s2) max. 7 m/s2 (23 ft/s2) max. 15 m/s2 (49 ft/s2)
(13.2 to 100 Hz) sinusoidal (13.2 to 100 Hz) sinusoidal (9 to 200 Hz) sinusoidal
Shock (IEC 60068-2-29) Not allowed Max. 100 m/s2 (330 ft./s2), Max. 100 m/s2 (330 ft./s2),
11 ms 11 ms
Free fall Not allowed 250 mm (10 in.) for weight 250 mm (10 in.) for weight
under 100 kg (220 lb) under 100 kg (220 lb)
100 mm (4 in.) for weight 100 mm (4 in.) for weight
over 100 kg (220 lb) over 100 kg (220 lb)
Materials
Module • PC/ABS 2.5 mm, colour NCS 1502-Y (RAL 90021 / PMS 420 C) Colour NCS 1502-Y
(RAL 90021 / PMS 420 C),
• hot-dip zinc coated steel sheet 1.5 to 2.5 mm, thickness of coating 20 micrometres
Busbars Tin plated copper (AC and DC busbars), or silver plated copper (quick connector and the
module counterpart)
Packaging Frame of wood or plywood with PE-LD wrapping and PP or steel bands.
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 will be 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.
Applicable standards
Markings

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RMIO board specifications

Analogue inputs
Two programmable differential current inputs (0 mA / 4 mA ... 20 mA, Rin = 100 ohm)
and one programmable differential voltage input (-10 V / 0 V / 2 V ... +10 V, Rin >
200 kohm).
The analogue inputs are galvanically isolated as a group.
Isolation test voltage 500 VAC, 1 min
Max. common mode voltage ±15 VDC
between the channels
Common mode rejection ratio > 60 dB at 50 Hz
Resolution 0.025% (12 bit) for the -10 V ... +10 V input. 0.5% (11 bit) for the 0 ... +10 V and 0 ...
20 mA inputs.
Inaccuracy ± 0.5% (Full Scale Range) at 25 °C (77 °F). Temperature coefficient: ± 100 ppm/°C
(± 56 ppm/°F), max.
Constant voltage output

Voltage +10 VDC, 0, -10 VDC ± 0.5% (Full Scale Range) at 25 °C (77 °F). Temperature
coefficient: ± 100 ppm/°C (± 56 ppm/°F) max.
Maximum load 10 mA
Applicable potentiometer 1 kohm to 10 kohm
Auxiliary power output

Voltage 24 VDC ± 10%, short circuit proof
Current consumption 250 mA (without any optional modules inserted onto slots 1 and 2); 1.2 A max
Analogue outputs
Two programmable current outputs: 0 (4) to 20 mA, RL < 700 ohm
Resolution 0.1% (10 bit)
Inaccuracy ± 1% (Full Scale Range) at 25 °C (77 °F). Temperature coefficient: ± 200 ppm/°C
(± 111 ppm/°F) max.
Digital inputs
With six programmable digital inputs (common ground: 24 VDC, -15% to +20%).
Group isolated, can be divided in two isolated groups (see Isolation and grounding
diagram below).
Thermistor input: 5 mA, < 1.5 kohm “1” (normal temperature), > 4 kohm “0”
(high temperature), open circuit “0” (high temperature).
Internal supply for digital inputs (+24 VDC): short circuit proof. An external 24 VDC
supply can be used instead of the internal supply.
Isolation test voltage 500 VAC, 1 min
Logical thresholds < 8 VDC “0”, > 12 VDC “1”
Input current DI1 to DI 5: 10 mA, DI6: 5 mA
Filtering time constant 1 ms

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Relay outputs
Three programmable relay outputs
Switching capacity 8 A at 24 VDC or 250 VAC, 0.4 A at 120 VDC
Minimum continuous current 5 mA rms at 24 VDC
Maximum continuous current 2 A rms
Isolation test voltage 4 kVAC, 1 minute
DDCS fibre optic link

With optional communication adapter module RDCO. Protocol: DDCS (ABB
Distributed Drives Communication System)
24 VDC power input
Voltage 24 VDC ± 10%
Typical current consumption 250 mA
(without optional modules)
Maximum current consumption 1200 mA (with optional modules inserted)
The terminals on the RMIO board as well as on the optional modules attachable to the board fulfil the Protective Extra
Low Voltage (PELV) requirements stated in EN 50178 provided that the external circuits connected to the terminals also
fulfil the requirements.

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Isolation and grounding diagram
(Test voltage: 500 V AC)

X20
1 VREF-
2 AGND
X21
1 VREF+
2 AGND
3 AI1+
4 AI1- Common mode
voltage between
5 AI2+
channels ±15 V
6 AI2-
7 AI3+
8 AI3-
9 AO1+
10 AO1-
11 AO2+
12 AO2-
X22
1 DI1
2 DI2
3 DI3
4 DI4
Jumper J1 settings:
9 DGND1
5 DI5 All digital inputs share a common

J1
6 DI6 ground. This is the default setting.
7 +24VD
8 +24VD Grounds of input groups
11 DIIL DI1…DI4 and DI5/DI6/DIIL
or
are separate (isolation
10 DGND2 voltage 50 V).
X23
1 +24 V
2 GND
X25
1 RO1
2 RO1
3 RO1
X26
1 RO2
2 RO2
3 RO2
X27
1 RO3
2 RO3
3 RO3
(Test voltage:
4 kV AC)
Ground

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Power consumption of auxiliary devices
Boards
Un Un f In Imax
Type
V DC V AC Hz A A
APBU-44 24 – – 0.2 –
NPBU-42 24 – – 0.2 0.235
RDCU-02 24 – – 0.25 1.2
Cooling fans
Un f In Istart
Frame size Type
V AC Hz A A
50 0.7 1.4
R2E225-BD92-12 230
R7i 60 0.7 1.4
R2E225-BD40-21 115 60 1.8 3.6
400 50 1.3 2.6
R8i D2D160-BE02-11
320 60 1.8 3.6
Un f In Istart
Filter type Type
V AC Hz A A
ALCL-04-5 R2E190-AE77-50 230 50 0.26 0.52
ALCL-05-5 R2E190-AE77-50 230 50 0.26 0.52
ALCL-04-7 R2E190-AE77-50 230 50 0.26 0.52
ALCL-05-7 R2E190-AE77-50 230 50 0.26 0.52
400 50 1.3 2.6
ALCL_2x_xx D2D160-BE02-11
320 60 1.8 3.6
230 50 0.78 1.6
ALCL_1x_xx R2E225-PD-92-12
230 60 1.12 2.2
US patents
This product is protected by one or more of the following US patents
4,920,306 5,301,085 5,463,302 5,521,483 5,532,568 5,589,754
5,654,624 5,799,805 5,940,286 5,942,874 5,952,613 6,094,364
6,147,887 6,175,256 6,184,740 6,195,274 6,229,356 6,252,436
6,265,724 6,305,464 6,313,599 6,316,896 6,335,607 6,370,049
6,396,236 6,448,735 6,498,452 6,552,510 6,597,148 6,741,059
6,774,758 6,844,794 6,856,502 6,859,374 6,922,883 6,940,253
6,934,169 6,956,352 6,958,923 D 503,931
Other patents are pending.

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This chapter contains two circuit diagram sets of cabinet-installed IGBT supply units.
First set presents the supply unit which is equipped with one R7i supply module. The
other set presents a supply unit which is equipped with two R8i supply modules. This
set also presents the inverter unit which includes two R8i inverter modules.
The example diagram sets help in understanding the internal connections and
operation of the IGBT supply unit. They are not intended for wiring or diagnostic
purposes as they most probably differ from a customised drive. The customer
specific diagrams are attached to the delivery of a cabinet-installed unit.
The most commonly used line side control devices are included in both diagram
sets: a main breaker/contactor, a three-position operating switch and a reset button.
In R7i diagrams, most options are included: meters on cabinet door, grounding
switch, supply transformer tripping circuit, control board backup battery (RAPI board)
etc.
In 2×R8i diagrams, options are not included. The inverter unit I/O signals are
connected according to ACS800 System Application Program.

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Supply unit with module R7i

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Drive with 2×R8i supply and 2×R8i inverter modules

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3AFE68233810 Rev B / EN
EFFECTIVE: 60.12.2005
ABB Oy
AC Drives
P.O. Box 184
FIN-00381 HELSINKI
FINLAND
Telephone +358 10 22 11
Fax +358 10 22 22681
Internet http://www.abb.com

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General drive manuals (in all deliveries)

 2005 ABB Oy. All Rights Reserved.

ACS800 Multidrive Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

About this manual

How the IGBT supply unit operates

IGBT supply module type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Technical data - ACS800-207

Technical data - ACS800-104 IGBT supply module

Auxiliary power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

IGBT supply unit example circuit diagrams

About this manual

What this chapter contains

About this manual

Categorization according to frame sizes

About this manual

How the IGBT supply unit operates

What this chapter contains

AC fuses Line filter IGBT supply module DC fuses

How the IGBT supply unit operates

AC voltage and current waveforms

THD Voltage [%]

How the IGBT supply unit operates

What this chapter contains

Layout of an ACS800 multidrive with an IGBT supply unit

Supply with frame R7i module

B IGBT supply module cabinet

7 C Inverter cabinet(s): See ACS800-107 Hardware

Supply with two frame R8i modules

Doors open C IGBT supply module cabinet

Supply with one frame R7i or R8i module

1) Power supply for LCL filter and IGBT

Supply with two frame R8i modules

IGBT supply module, frame R7i

4 X41 Socket for fan power supply

6 V1,V2 Fibre optic connectors for control board

7 3 Socket for fan control. Not in use.

4 Socket for fan power supply

6 Fibre optic connectors for control board (external)

Printed circuit boards

IGBT supply module

Fan power supply

RDCU Drive control unit

RMIO Converter control board

APOW Power supply board

NRED Voltage reduction board (in 690 VAC units only)

AINT Main circuit interface board

AGDR Gate driver board

IGBT supply module, frame R8i

3 2 Current transformers (one for each phase for

3 (V1,V2) Fibre optic connectors for control board

4 (X50) Quick connector for cooling fan power supply

M I 5 (+, -) Busbars for power output connections (DC)

4 Retractable support legs

Printed circuit boards

IGBT supply module

RMIO Converter control board

APOW Power supply board

NRED Voltage reduction board (in 690 VAC units only)

AINT Main circuit interface board

AGDR Gate driver board

LCL filter module types ALCL-04-05, -05-05, -04-07 or -05-07

4 Terminal for module temperature