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Hardware Manual
ACS800-607 3-phase Brake Units
List of related manuals
General manuals Code (English)
ACS800 Multidrive and Multidrive Modules Safety Instructions 3AFE64760432
ACS800 Multidrive Cabinet-installed Drives Mechanical Installation 3AFE68233402
ACS800 Multidrive and Multidrive Modules Planning the Electrical Installation 3AFE64783742
You can find manuals and other product documents in PDF format on the Internet. See section Document library on the
Internet on the inside of the back cover. For manuals not available in the Document library, contact your local ABB
representative.
ACS800-607 3-phase Brake Units
Hardware Manual
3AFE68925916 Rev C
EN
EFFECTIVE: 2016-03-18
Table of contents
Table of contents
Hardware description
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operation basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Brake chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Brake chopper control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Capacitor bank pre-charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Main circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Brake unit hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Layout drawing - bottom cable entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Layout drawing - top cable entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Brake module R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Brake module R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Power connections and control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
RMIO board connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Type designation labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Type code of the brake unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Basic code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Option codes (plus codes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Type code of the brake module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Basic code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Option codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Table of contents
6
Installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Checking the insulation of the resistor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Connecting the resistor cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Connection diagram – three-conductor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Connection diagram – four-conductor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Wiring the fault indication from relay output RO1 to the main breaker . . . . . . . . . . . . . . . . . .36
Control cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Installation of optional modules and PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
PC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Cabling of fieldbus modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Fibre optic links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Start-up
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Start-up checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Fault tracing
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
LEDs of the brake unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Maintenance
Reduced run capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Technical data
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Table of contents
7
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Input and output voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Type equivalences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Dimensions, noise, losses and cooling air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Resistor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Resistor cable connection and lead-through data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Tightening torques for power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Compliance with the Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
UL and CSA markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Dimensional drawings
R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Bottom cable exit and entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Top cable exit and entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Table of contents
8
Table of contents
9
Compatibility
The manual is compatible with ACS800-607 cabinet-installed brake units based on
inverter modules.
Target audience
This manual is intended for people who plan the installation, install, commission, use
and service the brake units. Read the manual before working on the units. The
reader is expected to know the fundamentals of electricity, wiring, electrical
components and electrical schematic symbols.
Safety
Follow the safety instructions delivered with the drive.
• Read the complete safety instructions before you install, commission, or use
the brake unit. The complete safety instructions are given in ACS800 Multidrive
and Multidrive Modules 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 the task specific safety instructions before starting the task. See the
section describing the task.
WARNING! The main breaker of the drive must be opened in case relay output RO1
is de-energized. This is the only way to guarantee safe operation since in case of a
chopper failure the chopper is unable to disconnect the resistor from the
intermediate circuit. See page 20.
Contents
Hardware description
Planning the installation
Installation
Start-up
Fault tracing
Maintenance
Technical data
Example circuit diagrams
Dimensional drawings.
Related manuals
See the inside of the front cover.
Task See
Select the cables and brake resistors. Selecting the brake resistors, page 28, Placing the brake
resistors, page 29 and Selecting and routing the brake
resistor cables, page 29
Plan the installation. ACS800 Multidrive and Multidrive Modules Planning the
Electrical Installation (3AFE64783742 [English])
Check that all necessary optional modules and equipment If the drive has been non-operational for more than one
are present and correct. year, the DC link capacitors need to be reformed. Ask ABB
Only intact units may be started up. for instructions.
Check the installation site and Install the unit mechanically. ACS800 Multidrive Mechanical Installation
(3AFE68233402 [English]).
Route the cables. ACS800 Multidrive and Multidrive Modules Planning the
Electrical Installation (3AFE64783742 [English]), Selecting
and routing the brake resistor cables, page 29
Check the insulation of the resistor circuit. Checking the insulation of the resistor circuit, page 32
Connect the resistor cables. Connect the control and the Installation, page 31
auxiliary control cables.
Commission the drive and the brake unit. Start-up, page 41, Brake Control Program Firmware Manual
(3AFE68835631 [English])
Hardware description
Operation basics
Typically, the multidrive is equipped with a brake unit if:
• high capacity braking is needed and the drive cannot be equipped with a
regenerative supply unit
• a backup for the regenerative supply unit is needed.
The brake unit includes a brake chopper (brake module) or several parallel-
connected brake choppers. The brake chopper is actually a three-phase inverter
module (ACS800-104) that is connected and controlled in a particular way: The input
of the module is connected to the DC link of the drive directly and each output phase
connects to the DC link via a brake resistor.
Fuses
The brake unit is equipped with fuses as standard. The fuses protect the chopper
and the brake circuit cables in a cable short-circuit situation.
Brake chopper
The chopper connects the brake resistor to the intermediate circuit whenever the
voltage in the intermediate circuit (DC bus) exceeds the maximum limit which is
defined with a parameter setting in the Brake Control Program.
Energy consumption by the resistor losses lowers the voltage until the resistor can
be disconnected. The energy generated by the motor during a fast deceleration of
the drive typically causes the voltage to rise in the intermediate circuit.
Brake resistors
The brake resistors dissipate the surplus energy conducted by the choppers. The
brake units must be equipped with brake resistors by the user. The resistor types to
be used are specified in chapter Technical data.
Hardware description
14
For more information on the brake chopper control, operation, settings, diagnostics
and protections, see Brake Control Program Firmware Manual
(3AFE68835631 [English]).
Resistor fuses
U2 V2 W2
Cabinet PE
ACS800-607
Hardware description
15
View from front, door closed View from front, door open
shrouds removed
No. Description
3 DC+ fuses
4 Resistor fuses
9
5 Brake module
Hardware description
16
View from front, door closed View from front, door open
shrouds removed
No. Description
4 Brake module
8 Resistor fuses
Hardware description
17
1 Item Explanation
1 DC (input) connections.
4
2
Hardware description
18
1
3
5
2
Item Explanation
1 DC (input) connections
2 Output busbars. These couple with the quick connector socket mounted in the cubicle
3 Fibre optic connectors of the AINT board. Connected to the RDCU drive control unit (via
an APBU branching unit in case of parallel modules)
5 Handle
6 Cooling fan
Hardware description
19
Slot 2
Hardware description
20
Hardware description
21
No. Description
1. Serial number. The first digit of the serial number refers to the manufacturing plant. The next
four digits refer to the unit’s manufacturing year and week, respectively. The remaining digits
complete the serial number so that there are no two units or modules with the same number.
2. Type code. See sections Type code of the brake unit on page 22 and Type code of the brake
module on page 25.
3. Valid markings
4
3
2 1
5
6
2
3 1
Hardware description
22
Note: The information below is for quick reference only and does not contain all
conditions and details. For more information, contact the local ABB representatives.
Basic code
Digit Name/Description Alternatives
1…6 Product series ACS800
8…10 Product type 607 cabinet-installed brake unit
12…15 Size 0250…6500
17 Voltage rating 3 – Voltage range 380…415 V AC
5 – Voltage range 380…500 V AC
7 – Voltage range 525…690 V AC
Hardware description
23
Hardware description
24
Hardware description
25
Basic code
Digit Name/Description Alternatives
1…6 Product series ACS800
8…10 Product type 104 inverter, supply and brake module
12…15 Size 0175…0580
17 Voltage rating 3 – Voltage range 380…415 V AC
5 – Voltage range 380…500 V AC
7 – Voltage range 525…690 V AC
Option codes
Ident. Alternatives Description
letter
C +C126 Speed-controlled cooling fan supplied from the DC bus. Available
for frame R8i only.
E +E205 Internal output (du/dt) filter. Not available for frame R7i. Standard
with frame R8i.
G +G304 115 V AC control voltage. Frame R7i only. (This option is not
applicable to frame R8i which is suitable for 230/115 V.)
V +V991 Current hardware variant. Frame R8i only.
In brake units consisting of parallel-connected frame R8i modules,
either all or none of the modules must have this option. In a single-
module unit, modules with or without this code are
interchangeable.
Hardware description
26
Hardware description
27
Note: The installation must always be designed and made according to applicable
local laws and regulations. ABB does not assume any liability whatsoever for any
installation which breaches the local laws and/or other regulations. Furthermore, if
the recommendations given by ABB are not followed, the drive may experience
problems that the warranty does not cover.
Mechanical installation
The brake unit forms one section in the cabinet line-up. For the mechanical
installation of the line-up see the manual ACS800 Liquid-cooled Multidrive
Mechanical Installation (3AFE68715466 [English]).
For the installation of the brake resistors, follow the instructions provided by the
resistor manufacturer.
Short-circuit protection
The brake unit is equipped with input and output fuses to protect the chopper, the
resistor and the brake circuit cables in a cable short-circuit situation.
Instruction
Protect against brake resistor overtemperature and brake chopper failure situations
as follows:
• Equip each brake resistor with an overtemperature sensor of its own.
• Wire the sensors to digital input DI1 on the RMIO board.
• Wire relay output RO1 to the main breaker and always switch off the power
supply to the drive when relay output RO1 is de-energized. Note: This is the only
way to guarantee safe operation since in case of a chopper failure the chopper is
unable to disconnect the resistor from the intermediate DC circuit.
• Set parameter 16.11 SUPPLY NETWORK to according to the electrical power
system.
For more information, see Brake Control Program Firmware Manual
(3AFE68835631 [English]).
Note: ABB has not verified that the EMC requirements are fulfilled with external
user-defined brake resistors and cabling. The EMC compliance of the complete
installation must be considered by the user.
Installation
Safety
Safety
WARNING! Only qualified electricians are allowed to carry out the installation.
All safety instructions must be followed during the work. See the manual ACS800
Multidrive and Multidrive Modules Safety Instructions (3AFE64760432 [English]).
Ignoring the safety instructions can cause injury or death, or damage to the
equipment.
WARNING! Make sure that the drive system is disconnected from the input power
during installation. If the drive system is already connected to the mains, wait for
5 min after disconnecting mains power. Measure the voltage between the DC
busbars/cables and earth with a multimeter (impedance at least 1 Mohm) to ensure
that the drive system is discharged before beginning work.
Mechanical installation
The brake unit forms one section in the cabinet line-up. For the mechanical
installation of the line-up see ACS800 Multidrive Mechanical Installation
(3AFE68233402 [English]).
For the installation of brake resistors, follow the instructions provided by the resistor
manufacturer.
Installation
32
R-
ohm
PE
Installation
33
WARNING! With aluminum cables, apply grease to the stripped conductors before
attaching them to non-coated aluminum cable lugs. Obey the grease manufacturer’s
instructions. Aluminum-aluminum contact can cause oxidation of the contact
surfaces.
1. Open the door of the brake module cubicle: Unlock the handle, release it from the
holder and turn upwards to release the door locking mechanism.
2. Remove the shroud that protects the output busbars and cable entries.
3. Units with bottom entry/exit: Unplug the socket of the cooling fan and remove the
cooling fan.
4. Lead the cables into the inside of the cubicle. For minimum radio frequency
interference and motor bearing current, ground the cable shield 360° at the lead-
through.
5. Connect the cables as follows:
• Cut the cables to suitable length. Strip the cables and conductors. Fasten the
cable lugs to the conductor ends.
• Twist the cable shields into bundles and connect them to the cabinet PE
busbar.
• Connect the conductors to the terminals as shown on the diagram below.
• Tighten the resistor and PE conductors to 70 N·m (50 lbf·ft) torque.
6. Plug in the fan power supply and refit the fan.
7. Refit the shroud removed earlier and close the door.
Installation
34
DC+
DC -
F6.1 F6.2
F6.11
ACS800-104
U2 V2 W2
R3.2
ACS800-607
Notes:
For selection of the resistor cables, see section Resistor cable on page 54.
Pay special attention to the grounding of the cable. 360° earthing is to be used at cable entries.
For the resistor cable terminal sizes, cabinet lead-through sizes and tightening torques, see section Resistor cable
connection and lead-through data on page 55.
Tightening torque is 70 N·m (52 lbf·ft).
For resistor overheating protection, see page 20.
WARNING! Never connect the output terminals of the brake chopper together. It
short-circuits the chopper and will damage it.
Installation
35
DC+
DC -
F6.1 F6.2
ACS800-104 F6.11
U2 V2 W2
ACS800-607
Notes:
For selection of the resistor cables, see section Resistor cable on page 54.
Pay special attention to the grounding of the cable. 360° earthing is to be used at cable entries.
For the resistor cable terminal sizes, cabinet lead-through sizes and tightening torques, see section Resistor cable
connection and lead-through data on page 55.
Tightening torque is 70 N·m (52 lbf·ft).
For resistor overheating protection, see page 20.
WARNING! Never connect the output terminals of the brake chopper together. It
short-circuits the chopper and will damage it.
Installation
36
Wiring the fault indication from relay output RO1 to the main breaker
A principle of wiring the fault indication from relay output RO1 to the main breaker
control is shown below.
L1 L2 L3
1
0 K 1
S1
2
13 1 3 5
K1
S1 1 3
14 2 4 6 Main breaker
1 2 4
0 K
1 3
RMIO
K × × X25
1 × 2
0
3
K1
Installation
37
Side view
Strain relief EMI conductive
cushions
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).
Copper foil
Grounding wire
On top entry units, sort the cables so that the thinnest and thickest cables are at opposite ends of the
opening.
Top view
Installation
38
Run the cables to the appropriate terminals. Wherever possible, use the existing cable trunking in the
cabinet. Use sleeving wherever the cables are laid against sharp edges.
Note: When running cables to the swing-out frame, leave some slack in the cable at the hinge to allow the
frame to open fully. Tie the cables to the cable supports wherever necessary.
Cut the cables to suitable length. Strip the cables and conductors.
Twist the cable shields into bundles and connect them to the ground terminal nearest to the terminal block.
Keep the unshielded portion of the cables as short as possible.
Connect the conductors to appropriate terminals (see the circuit diagrams delivered with the unit).
Refit any shrouds removed earlier. Close the cabinet door(s).
WARNING! Read and follow the safety instructions, given in ACS800 Multidrive and
Multidrive Modules Safety Instructions (3AFE64760432 [English]). Ignoring the
instructions can cause physical injury or death, or damage to the equipment.
PC connection
Connect PC to CH3 of RDCO board via a fibre optic link. RDCO is attached to an
option slot of the RDCU unit. See also Fibre optic links below.
Optional modules
Insert optional modules (such as fieldbus adapters) into the optional module slots of
the RDCU unit and secure with two screws. The slots on the RDCU unit are
described in Power connections and control interfaces on page 19. See also the
appropriate optional module manual for information on the cable connections.
Cabling of fieldbus modules
Module
Keep unshielded portion as
short as possible
Shield
1
2
3
4
To nearest PE terminal
Installation
39
Installation
40
Installation
41
Start-up
WARNING! The work described in this chapter must only be carried out by a
qualified electrician. The directions given in ACS800 Multidrive and Multidrive
Modules Safety Instructions (3AFE64760432 [English]) must be followed.
Neglecting the safety instructions can cause injury or death.
Start-up checklist
Action Additional information
Preliminary actions
WARNING! Ensure that the disconnector of the supply transformer is locked to open position, i.e. no voltage is, or
can be, connected to the drive inadvertently. Check also by measuring that there is no voltage connected.
Check that the mechanical and electrical installation of the brake resistor See chapters Planning the installation
has been inspected and is OK. and Installation.
Check that the insulation of the resistor circuit has been measured and is See section Checking the insulation
OK. of the resistor circuit on page 32.
Ensure that the surroundings and the inside of the cabinet are free from
dust and loose objects like cable trimmings and other waste left from the
installation.
Check that the drive is ready for the brake unit start-up, i.e.: See the appropriate manuals from the
• The drive has been installed according to the instructions given in the list on the inside of the front cover.
hardware manual.
• The supply unit has been commissioned according to the instructions
given in the appropriate supply unit manual.
• The inverter units have been commissioned according to the
instructions given in the hardware manual and appropriate firmware
manual.
Close all cabinet doors.
Start-up
42
Start-up
43
Fault tracing
RMIO board (RDCU drive control Red Brake chopper in fault state.
unit)
Green The power supply on the board is OK.
Control panel mounting platform Red Brake chopper in fault state.
(with the control panel removed)
Green The main +24 V power supply for the control panel and the
RMIO board is OK.
AINT board (visible through the V204 (green) +5 V voltage of the board is OK.
transparent cover on the front of the
V309 (red) -
brake modules)
V310 (green) IGBT control signal transmission to the gate driver control
boards is enabled.
APBU board “RXD” led Data is being received from RDCU drive control unit.
“TXD” led Data is being sent to RDCU drive control unit.
“BAT” led Memory backup battery voltage is OK.
“PWR” led 5 V power to on-board logic is OK.
Fault tracing
44
Fault tracing
45
Maintenance
Note: When a brake unit with parallel-connected brake modules is equipped with
one RMIO board only, a fault in one brake module trips the whole brake unit.
In units with brake modules equipped with their own RMIO boards, only the faulted
brake module trips and the drive continues running with the remaining brake
modules without parameter settings. However, when relay output RO1 is de-
energized, the main breaker of the whole drive must be opened. See page 36. For
more information on the protection, see the Brake Control Program Firmware
Manual (3AFE68835631 [English]).
Maintenance
46
Maintenance
47
Technical data
Ratings
The rating tables are given below.
Unit type Frame Resistor values Ratings with Rmin
size No-overload use Cycle load (1min/5min)
Rmin Rmax Idc Irms Pcontmax Imax Idc Irms Pbr
Ohm Ohm A DC A DC kW A DC A DC A DC kW
UN=400 V
ACS800-607-0250-3 R7i 3.5 4.1 390 155 250 185 500 176 320
ACS800-607-0500-3 R8i 1.7 2.1 781 310 500 370 999 351 640
ACS800-607-0750-3 R8i 1.2 1.4 1171 465 750 555 1499 527 960
ACS800-607-1000-3 2×R8i 1.7 2.1 1562 621 1000 740 1998 702 1290
ACS800-607-1510-3 2×R8i 1.2 1.4 2342 931 1510 1110 2997 1053 1930
ACS800-607-2260-3 3×R8i 1.2 1.4 3514 1396 2260 1665 4496 1580 2890
ACS800-607-3010-3 4×R8i 1.2 1.4 4685 1862 3010 2220 5994 2106 3860
ACS800-607-3770-3 5×R8i 1.2 1.4 5856 2327 3770 2775 7493 2633 4820
UN=500 V
ACS800-607-0310-5 R7i 4.3 5.2 390 155 310 185 500 176 400
ACS800-607-0630-5 R8i 2.2 2.6 781 310 630 370 999 351 800
ACS800-607-0940-5 R8i 1.4 1.7 1171 465 940 555 1499 527 1210
ACS800-607-1260-5 2×R8i 2.2 2.6 1562 621 1260 740 1998 702 1610
ACS800-607-1880-5 2×R8i 1.4 1.7 2342 931 1880 1110 2997 1053 2410
ACS800-607-2830-5 3×R8i 1.4 1.7 3514 1396 2830 1665 4496 1580 3620
ACS800-607-3770-5 4×R8i 1.4 1.7 4685 1862 3770 2220 5994 2106 4820
ACS800-607-4710-5 5×R8i 1.4 1.7 5856 2327 4710 2775 7493 2633 6030
UN=690 V
ACS800-607-0430-7 R7i 6.0 7.1 390 155 430 185 500 176 550
ACS800-607-0870-7 R8i 3.0 3.6 781 310 870 370 999 351 1110
ACS800-607-1300-7 R8i 2.0 2.4 1171 465 1300 555 1499 527 1660
ACS800-607-1730-7 2×R8i 3.0 3.6 1562 621 1730 740 1998 702 2220
ACS800-607-2600-7 2×R8i 2.0 2.4 2342 931 2600 1110 2997 1053 3330
ACS800-607-3900-7 3×R8i 2.0 2.4 3514 1396 3900 1665 4496 1580 4990
ACS800-607-5200-7 4×R8i 2.0 2.4 4685 1862 5200 2220 5994 2106 6650
ACS800-607-6500-7 5×R8i 2.0 2.4 5856 2327 6500 2775 7493 2633 8320
00184674.xls / H.29
Technical data
48
Technical data
49
Symbols
Resistor
Rmin Minimum allowed resistance value of the brake resistor per one phase of the brake module
Rmax Maximum resistance value of the brake resistor per one phase of the brake module
Note: Connect one resistor per brake module phase. For example, a brake unit of frame size
2×R8i includes two brake modules -> 2 × 3 resistors are needed.
Peak brake current
Imax Peak brake current (DC) per chopper module phase
No-overload use
Imax Peak brake current (DC) per chopper module phase
Pcont.max Maximum continuous braking power per brake unit
Imax
Irms
Pbrcont
0 0
0 0
1 min 4 min
1 min 4 min
DC+
DC -
Idc1 Idc2
ACS800-104 ACS800-104
U2 V2 W2 U2 V2 W2
Irms1 Irms2
Technical data
50
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 · I2N or 0.90 · I2hd.
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.
Technical data
51
Type equivalences
Brake unit type Basic brake module
No. and
Type
size
UN = 400 V
ACS800-607-0250-3 ACS800-104-0175-3 R7i
ACS800-607-0500-3 ACS800-104-0320-3 R8i
ACS800-607-0750-3 ACS800-104-0510-3 R8i
ACS800-607-1000-3 ACS800-104-0320-3 2×R8i
ACS800-607-1510-3 ACS800-104-0510-3 2×R8i
ACS800-607-2260-3 ACS800-104-0510-3 3×R8i
ACS800-607-3010-3 ACS800-104-0510-3 4×R8i
ACS800-607-3770-3 ACS800-104-0510-3 5×R8i
UN = 500 V
ACS800-607-0310-5 ACS800-104-0215-5 R7i
ACS800-607-0630-5 ACS800-104-0400-5 R8i
ACS800-607-0940-5 ACS800-104-0610-5 R8i
ACS800-607-1260-5 ACS800-104-0400-5 2×R8i
ACS800-607-1880-5 ACS800-104-0610-5 2×R8i
ACS800-607-2830-5 ACS800-104-0610-5 3×R8i
ACS800-607-3770-5 ACS800-104-0610-5 4×R8i
ACS800-607-4710-5 ACS800-104-0610-5 5×R8i
UN = 690 V
ACS800-607-0430-7 ACS800-104-0215-7 R7i
ACS800-607-0870-7 ACS800-104-0400-7 R8i
ACS800-607-1300-7 ACS800-104-0580-7 R8i
ACS800-607-1730-7 ACS800-104-0400-7 2×R8i
ACS800-607-2600-7 ACS800-104-0580-7 2×R8i
ACS800-607-3900-7 ACS800-104-0580-7 3×R8i
ACS800-607-5200-7 ACS800-104-0580-7 4×R8i
ACS800-607-6500-7 ACS800-104-0580-7 5×R8i
00184674.xls / H.29
Technical data
52
Technical data
53
Fuses
DC+ and DC- fuses Resistor fuses
Brake unit type Type by Type by Ferraz Type by Type by Ferraz
Qty Qty
Bussmann Shawmut Bussmann Shawmut
UN = 400 V
ACS800-607-0250-3 170M6544 PC93UD18C630TF 2 170L5117 PC93UF15C315TF 3
ACS800-607-0500-3 170M6544 PC93UD18C630TF 4 170L9868 PC93UD18C630TF 3
ACS800-607-0750-3 170M6548 PC93UD17C1000TF 4 170M6734 PC93UD18C850TF 3
ACS800-607-1000-3 170M6544 PC93UD18C630TF 8 170L9868 PC93UD18C630TF 6
ACS800-607-1510-3 170M6548 PC93UD17C1000TF 8 170M6734 PC93UD18C850TF 6
ACS800-607-2260-3 170M6548 PC93UD17C1000TF 12 170M6734 PC93UD18C850TF 9
ACS800-607-3010-3 170M6548 PC93UD17C1000TF 16 170M6734 PC93UD18C850TF 12
ACS800-607-3770-3 170M6548 PC93UD17C1000TF 20 170M6734 PC93UD18C850TF 15
UN = 500 V
ACS800-607-0310-5 170M6544 PC93UD18C630TF 2 170L5117 PC93UF15C315TF 3
ACS800-607-0630-5 170M6544 PC93UD18C630TF 4 170L9868 PC93UD18C630TF 3
ACS800-607-0940-5 170M6548 PC93UD17C1000TF 4 170M6734 PC93UD18C850TF 3
ACS800-607-1260-5 170M6544 PC93UD18C630TF 8 170L9868 PC93UD18C630TF 6
ACS800-607-1880-5 170M6548 PC93UD17C1000TF 8 170M6734 PC93UD18C850TF 6
ACS800-607-2830-5 170M6548 PC93UD17C1000TF 12 170M6734 PC93UD18C850TF 9
ACS800-607-3770-5 170M6548 PC93UD17C1000TF 16 170M6734 PC93UD18C850TF 12
ACS800-607-4710-5 170M6548 PC93UD17C1000TF 20 170M6734 PC93UD18C850TF 15
UN = 690 V
ACS800-607-0430-7 170M6544 PC93UD18C630TF 2 170L5117 PC93UF15C315TF 3
ACS800-607-0870-7 170M6544 PC93UD18C630TF 4 170L9868 PC93UD18C630TF 3
ACS800-607-1300-7 170M6548 PC93UD17C1000TF 4 170M6734 PC93UD18C850TF 3
ACS800-607-1730-7 170M6544 PC93UD18C630TF 8 170L9868 PC93UD18C630TF 6
ACS800-607-2600-7 170M6548 PC93UD17C1000TF 8 170M6734 PC93UD18C850TF 6
ACS800-607-3900-7 170M6548 PC93UD17C1000TF 12 170M6734 PC93UD18C850TF 9
ACS800-607-5200-7 170M6548 PC93UD17C1000TF 16 170M6734 PC93UD18C850TF 12
ACS800-607-6500-7 170M6548 PC93UD17C1000TF 20 170M6734 PC93UD18C850TF 15
3AXD00000184674 J20
Technical data
54
Resistor cable
The table below gives copper cable types. Cable sizing is based on max. 9 cables
laid on a cable ladder side by side, three ladder type trays one on top of the other,
ambient temperature 30 °C, PVC insulation, surface temperature 70 °C and 90 °C
(EN 60204-1 and IEC 60364-5-2/2001). For other conditions, size the cables
according to local safety regulations, appropriate input voltage and the load current
of the drive. Irms dim is the dimensioning current.
Brake unit type No. and size Irms dim Cable data*
of modules Cable, T=70 °C Cable, T=90 °C
2
A mm mm2
UN = 400 V
ACS800-607-0250-3 R7i 186 3×(3×120+70) 3×(3×95+50)
ACS800-607-0500-3 R8i 372 3×(2×(3×120+70)) 3×(3×240+120)
ACS800-607-0750-3 R8i 559 3×(2×(3×240+120)) 3×(2×(3×150+70))
ACS800-607-1000-3 2×R8i 745 2×(3×(2×(3×120+70))) 2×(3×(3×240+120))
ACS800-607-1510-3 2×R8i 1117 2×(3×(2×(3×240+120))) 2×(3×(2×(3×150+70)))
ACS800-607-2260-3 3×R8i 1676 3×(3×(2×(3×240+120))) 3×(3×(2×(3×150+70)))
ACS800-607-3010-3 4×R8i 2234 4×(3×(2×(3×240+120))) 4×(3×(2×(3×150+70)))
ACS800-607-3770-3 5×R8i 2793 5×(3×(2×(3×240+120))) 5×(3×(2×(3×150+70)))
UN = 500 V
ACS800-607-0310-5 R7i 186 3×(3×120+70) 3×(3×95+50)
ACS800-607-0630-5 R8i 372 3×(2×(3×120+70)) 3×(3×240+120)
ACS800-607-0940-5 R8i 559 3×(2×(3×240+120)) 3×(2×(3×150+70))
ACS800-607-1260-5 2×R8i 745 2×(3×(2×(3×120+70))) 2×(3×(3×240+120))
ACS800-607-1880-5 2×R8i 1117 2×(3×(2×(3×240+120))) 2×(3×(2×(3×150+70)))
ACS800-607-2830-5 3×R8i 1676 3×(3×(2×(3×240+120))) 3×(3×(2×(3×150+70)))
ACS800-607-3770-5 4×R8i 2234 4×(3×(2×(3×240+120))) 4×(3×(2×(3×150+70)))
ACS800-607-4710-5 5×R8i 2793 5×(3×(2×(3×240+120))) 5×(3×(2×(3×150+70)))
UN = 690 V
ACS800-607-0430-7 R7i 186 3×(3×120+70) 3×(3×95+50)
ACS800-607-0870-7 R8i 372 3×(2×(3×120+70)) 3×(3×240+120)
ACS800-607-1300-7 R8i 559 3×(2×(3×240+120)) 3×(2×(3×150+70))
ACS800-607-1730-7 2×R8i 745 2×(3×(2×(3×120+70))) 2×(3×(3×240+120))
ACS800-607-2600-7 2×R8i 1117 2×(3×(2×(3×240+120))) 2×(3×(2×(3×150+70)))
ACS800-607-3900-7 3×R8i 1676 3×(3×(2×(3×240+120))) 3×(3×(2×(3×150+70)))
ACS800-607-5200-7 4×R8i 2234 4×(3×(2×(3×240+120))) 4×(3×(2×(3×150+70)))
ACS800-607-6500-7 5×R8i 2793 5×(3×(2×(3×240+120))) 5×(3×(2×(3×150+70)))
Example
3×(2×(3×240+120))
Technical data
55
Efficiency
Approximately 98% at nominal power level
Cooling
Method Internal fans, flow direction from bottom to top
Cooling air flow See section Dimensions, noise, losses and cooling air flow above.
Degree of protection
IP22; IP42; IP54; IP54R (with air duct outlet)
Technical data
56
Ambient conditions
Environmental limits for the drive are given below. The drive is to be used in a heated, indoor,
controlled environment.
Max. 1 mm (0.04 in.) Max. 1 mm (0.04 in.) Max. 3.5 mm (0.14 in.)
Vibration (5 to 13.2 Hz), (5 to 13.2 Hz), (2 to 9 Hz),
(IEC 60068-2) 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
Not allowed Max. 100 m/s2 (330 ft/s2), 11 ms Max. 100 m/s2 (330 ft/s2), 11 ms
(IEC 60068-2-27)
250 mm (10 in.) for weight under 250 mm (10 in.) for weight under
100 kg (220 lb) 100 kg (220 lb)
Free fall Not allowed
100 mm (4 in.) for weight over 100 mm (4 in.) for weight over
100 kg (220 lb) 100 kg (220 lb)
Technical data
57
Materials
Cabinet Hot-dip zinc-coated (thickness approx. 20 µm) sheet steel with polyester thermosetting powder coating
(thickness approx. 80 µm) on visible surfaces except back panel. Colour: RAL 7035 (light grey,
semigloss).
Inverter modules • PC/ABS 2.5 mm, colour NCS 1502-Y (RAL 90021 / PMS 420 C)
• hot-dip zinc coated steel sheet 1.5 to 2 mm, thickness of coating 100 micrometres
• cast aluminium AlSi (R2i and R3i)
• extruded aluminium AlSi (R4i and R5i)
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 are classified as hazardous waste within the EU. They must be removed and
handled according to local regulations.
For further information on environmental aspects and more detailed recycling instructions, please
contact your local ABB distributor.
Applicable standards
See ACS800 Multidrive and Multidrive Modules Planning the Electrical Installation
(3AFE64783742 [English]).
CE marking
See ACS800 Multidrive and Multidrive Modules Planning the Electrical Installation
(3AFE64783742 [English]).
Technical data
58
Technical data
59
WARNING! These example diagrams are not intended for wiring or diagnostic
purposes as they most probably differ from a customised brake unit. The customer
specific diagrams are attached to the delivery of a cabinet-installed unit.
R7i
R8i
Dimensional drawings
R7i
Dimensional drawings
72
Dimensional drawings
73
Dimensional drawings
74
R8i
Dimensional drawings
75
Dimensional drawings
76
Dimensional drawings
77
Dimensional drawings
78
Dimensional drawings
79
Dimensional drawings
80
Dimensional drawings
Further information
Product and service inquiries
Address any inquiries about the product to your local ABB representative, quoting the type
designation and serial number of the unit in question. A listing of ABB sales, support and
service contacts can be found by navigating to www.abb.com/searchchannels.
Product training
For information on ABB product training, navigate to new.abb.com/service/training.
www.abb.com/drives
www.abb.com/drivespartners