EN / ACS800-04/04M/U4 Cabinet Installation

EN / ACS800-04/04M/U4 Cabinet Installation
ACS800
Cabinet Installation
ACS800-04 and ACS800-04M Drive Modules (45 to 560 kW)
ACS800-U4 Drive Modules (60 to 600 HP)
ACS800 Single Drive Manuals
HARDWARE MANUALS (appropriate manual is included in the
delivery)
ACS800-01/U1 Hardware Manual 0.55 to 160 kW (0.75 to 200 HP)
3AFE64382101 (English)
ACS800-01/U1/04 Marine Supplement 0.55 to 160 kW (0.75 to
200 HP) 3AFE64291275 (English)
ACS800-11/U11 Hardware Manual 5.5 to 110 kW (7.5 to 125 HP)
3AFE68367883 (English)
ACS800-31/U31 Hardware Manual 5.5 to110 kW (7.5 to 125 HP)
3AFE68599954 (English)
ACS800-02/U2 Hardware Manual 90 to 500 kW (125 to 600 HP)
3AFE64567373 (English)
ACS800-04/U4 Hardware Manual 0.55 to 160 kW (0.75 to 200 HP)
3AFE68372984 (English)
ACS800-04/04M/U4 Hardware Manual 45 to 560 kW (60 to
600 HP) 3AFE64671006 (English)
ACS800-04/04M/U4 Cabinet Installation 45 to 560 kW (60 to
600 HP) 3AFE68360323 (English)
ACS800-07/U7 Hardware Manual 45 to 560 kW (50 to 600 HP)
3AFE64702165 (English)
ACS800-07/U7 Dimensional Drawings 45 to 560 kW (50 to
600 HP) 3AFE64775421
ACS800-07 Hardware Manual 500 to 2800 kW
3AFE64731165 (English)
ACS800-17 Hardware Manual 55 to 2500 kW (75 to 2800 HP)
3AFE68397260 (English)
ACS800-37 Hardware Manual 55 to 2700 kW (75 to 3000 HP)
3AFE68557925 (English)
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Safety instructions
Electrical installation planning
Mechanical and electrical installation
Motor control and I/O board (RMIO)
Maintenance
Technical data
Dimensional drawings
Resistor braking
FIRMWARE MANUALS, SUPPLEMENTS AND GUIDES
(appropriate documents are included in the delivery)
Standard Control Program Firmware Manual
3AFE64527592 (English)
System Control Program Firmware Manual
3AFE64670646 (English)
Control Program Template Firmware Manual
3AFE64616340 (English)
Master/Follower 3AFE64590430 (English)
Pump Control Program Firmware Manual
3AFE68478952 (English)
Extruder Control Program Supplement 3AFE64648543 (English)
Centrifuge Control Program Supplement 3AFE64667246 (English)
Traverse Control Program Supplement 3AFE64618334 (English)
Crane Control Program Firmware Manual 3BSE11179 (English)
Adaptive Programming Application Guide
3AFE64527274 (English)
OPTION MANUALS (delivered with optional equipment)
Fieldbus Adapters, I/O Extension Modules etc.
ACS800-04 and ACS800-04M Drive Modules
45 to 560 kW
ACS800-U4 Drive Modules
60 to 600 HP
Cabinet Installation
3AFE68360323 Rev B EN
EFFECTIVE: 14.2.2008
© 2008 ABB Oy. All Rights Reserved.
5
Table of contents
ACS800 Single Drive Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table of contents
About this manual
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Other related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Categorization according to the frame size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Categorization according to the plus code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation, commissioning and operating flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
11
11
11
12
12
12
13
14
14
14
The ACS800-04/U4 and ACS800-04M
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The ACS800-04/U4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The ACS800-04M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type designation label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main circuit and control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections of the Drive Control Unit (RDCU) in frame sizes R7 and R8 . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
15
16
16
17
18
20
21
21
22
22
Planning the cabinet installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cabinet construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disposition of the devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Layout examples, door closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Layout examples, door open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding of mounting structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Busbar material and joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
23
23
24
25
26
26
26
Table of contents
6
Cabinet cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cabinet cooling data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IP 22 cabinet with no extra fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IP 54 cabinet with an extra fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventing the recirculation of hot air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inside the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cubicle heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required free space around the drive module for cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Free space at the top of the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Free space around units with busbars on the long side (bookshelf mounting +H354) . . . . . . .
Free space around units with busbars on the short side (flat mounting +H360) . . . . . . . . . . .
When the drive module is installed in another position than vertically . . . . . . . . . . . . . . . . . . . . . .
Drive module of frame size R7 on its side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive module of frame size R7 on its back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EMC requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding of cable shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Drive Control Unit (RDCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastening of the control panel (CDP312R) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the control panel directly on the cabinet door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Panel Mounting Platform RPMP-11/13 (+J410) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Panel Holder RPMP-21 (+J413) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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28
28
28
29
29
29
29
30
30
31
32
33
33
34
35
36
36
37
37
37
38
Mechanical installation of pre-assembled units (ACS800-04/U4)
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Moving and unpacking the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fasten the module to the cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clamping the pedestal with the outside brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fasten the terminals to the busbars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
View of output busbar connections of frame size R7 (DC and brake busbars included) . . .
View of output busbar connections of frame size R8 (DC and brake busbars included) . .
User connections of Prevention of Unexpected Start (+Q950) . . . . . . . . . . . . . . . . . . . . . . . . .
39
39
40
41
42
42
42
42
43
44
44
Mechanical installation of non-pre-assembled units (ACS800-04M)
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to read this chapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Units with bottom exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Units with pedestal and busbars on the long side (+H354, bookshelf mounting) . . . . . . . . . . .
Units with pedestal and busbars on the short side (+H360, flat mounting) . . . . . . . . . . . . . . . .
Required tools and tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Moving and unpacking the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of contents
45
45
45
45
45
46
46
7
Frame size R7 units with bottom exit (+H352) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastening the spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastening the top entry busbar and bottom exit shrouds (+B060) . . . . . . . . . . . . . . . . . . . . . . .
Top entry busbar shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bottom exit shroud
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Units with pedestal and busbars on the long side (+H354, bookshelf mounting) . . . . . . . . . . . . . .
Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Item packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Item packages of frame size R7 with busbars on the long side . . . . . . . . . . . . . . . . . . . . . . .
Item packages of frame size R8 with busbars on the long side . . . . . . . . . . . . . . . . . . . . . .
Assembling procedure for units with busbars on the long side (+H354) . . . . . . . . . . . . . . . . . . . . .
Working order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the DC busbars to the pedestal (+H356 and +H363 only) . . . . . . . . . . . . . . . . . . .
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Photos of frame size R7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Photos of frame size R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Busbars to the left- or right-hand side of the module? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swapping the busbars of the pedestal to the other side . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional selection +H363 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastening the pedestal to the cabinet base (not for wall-mounted units) . . . . . . . . . . . . . . . . . .
Clamping the pedestal with the outside brackets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastening the pedestal through the holes inside the pedestal . . . . . . . . . . . . . . . . . . . . . . . .
Fastening the drive module by top to the cabinet frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastening the drive module to wall (wall-mounted units only, not for base-mounted units) . . . .
Requirements for protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Requirements for the wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastening the output busbars and PE terminal and sliding the module in . . . . . . . . . . . . . . . . .
View of output busbar connections of frame size R7 (DC and brake busbars included) . . .
View of output busbar connections of frame size R8 (DC and brake busbars included) . . .
Fastening the drive module to the pedestal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastening the shrouds in frame size R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Top entry busbar shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vertical busbar shroud
....................................................
Units with pedestal and busbars on the short side (+H360, flat mounting) . . . . . . . . . . . . . . . . . . .
Delivery check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Item packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Item packages of frame size R7 with busbars on the short side . . . . . . . . . . . . . . . . . . . . . .
Item packages of frame size R8 with busbars on the short side . . . . . . . . . . . . . . . . . . . . .
49
49
53
55
55
55
56
57
57
57
58
64
73
73
76
76
76
77
78
78
79
80
80
80
81
81
81
81
81
82
86
87
88
89
90
90
90
91
91
91
92
98
Table of contents
8
Assembling procedure for units with busbars on the short side (+H360) . . . . . . . . . . . . . . . . . . .
Working order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Swapping the pedestal output busbars to the left-hand side . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the DC busbars to the pedestal (+H360 +H356 only) . . . . . . . . . . . . . . . . . . . . . .
Required parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preparing the adapter (+H360 +H356 only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Required parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastening the adapter to the drive module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastening the drive module to the pedestal via the adapter . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting the output busbars on the short side of the module . . . . . . . . . . . . . . . . . . . . . . .
Procedure for frame size R7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Procedure frame size R8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104
104
106
107
107
107
108
108
108
109
110
111
111
113
Checking the installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cabinet construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instrumentation, busbars and cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Groundings and protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Labels, switches, fuses and doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
115
115
115
115
117
118
Dimensional drawings
Frame size R7 without pedestal (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame size R7 with bottom exit (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame size R7 with bottom exit and top entry and bottom exit shrouds (mm) . . . . . . . . . . . . . .
Frame size R7 with busbars on the left side (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame size R7 with DC busbars on both sides (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame size R7 pedestal busbars on the long side (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame size R7 with busbars on the short side (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame size R8 without pedestal (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame size R8 with busbars on the left side (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame size R8 with top entry and vertical busbar shrouds (mm) . . . . . . . . . . . . . . . . . . . . . . . . .
Frame size R8 with busbars on both sides (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame size R8 pedestal busbars on the long side (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame size R8 with busbars on the short side (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wall mounting spacers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame size R7 bottom exit kit (+H352) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame size R7 top entry busbar shroud and bottom exit shroud (+B060) . . . . . . . . . . . . . . . . . .
Control Panel Holder RPMP-21 (+J413) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Control Unit (RDCU-02) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of contents
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
9
Dimensional drawings (USA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame size R7 without pedestal (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame size R7 with bottom exit (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame size R7 with bottom exit and top entry and bottom exit shrouds (inches) . . . . . . . . . . .
Frame size R7 with busbars on the left side (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame size R7 with busbars on both sides (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame size R7 pedestal busbars on the long side (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame size R7 with busbars on the short side (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame size R8 without pedestal (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame size R8 with busbars on the left side (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame size R8 with top entry and vertical busbar shrouds (inches) . . . . . . . . . . . . . . . . . . . . .
Frame size R8 with busbars on both sides (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame size R8 pedestal busbars on the long side (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame size R8 with busbars on the short side (inches) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
138
139
140
141
142
143
144
145
146
147
148
149
150
151
Circuit diagrams
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Assembly drawings
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adding UDC+/R+, UDC- and R- busbars to the pedestal (frame size R7, +H356+H360) . . . . . .
Adding UDC+/R+, UDC- and R- busbars to the adapter (frame size R7, +H356+H360) . . . . . . .
Adding UDC+/R+, UDC- and R- busbars to the pedestal (frame size R8, +H356+H360) . . . . . .
Adding UDC+/R+, UDC- and R- busbars to the adapter (frame size R8, +H356+H360) . . . . . . .
155
156
157
158
159
Table of contents
10
Table of contents
11
About this manual
What this chapter contains
This chapter describes the intended audience and contents of the manual. It
contains a flowchart of steps in checking the delivery, installing and commissioning
the drive. The flowchart refers to chapters/sections in this manual and other
manuals.
Target audience
This manual is intended for people who plan the installation, and install the drive
module into a user-defined cabinet. Read the manual before the installation work.
The reader is expected to know the fundamentals of electricity, wiring, electrical
components and electrical schematic symbols.
The manual is written for readers worldwide. Both SI and imperial units are shown.
Special US instructions for installations within the United States that must be
installed per the National Electrical Code and local codes are marked with (US).
Safety
WARNING! Follow the safety instructions given in ACS800-04/04M/U4 Hardware
Manual [3AFE64671006 (English)] when installing, operating and servicing the drive.
If ignored, physical injury or death may follow, or damage may occur to the drive, the
motor or driven equipment. Read the safety instructions before you work on the unit.
Other related manuals
See ACS800-04/04M/U4 Hardware Manual [3AFE64671006 (English)] for
information concerning the drive module such as
• safety
• planning the electrical installation
• electrical installation
• motor control and I/O board (RMIO)
• maintenance
• technical data
• resistor braking.
About this manual
12
For installation instructions of optional equipment, see their manuals.
For example installations in Rittal TS 8 cabinet, refer to ACS800-04/U4 Rittal TS 8
Cabinet Installation [3AFE68372330 (English)].
Categorization according to the frame size
The instructions, technical data and dimensional drawings which concern only
certain frame sizes are marked with the symbol of the frame size R7 or R8. The
frame size is not marked on the drive designation label. To identify the frame size of
your drive, see the rating tables in chapter Technical data in ACS800-04/04M/U4
Hardware Manual [3AFE64671006 (English)].
Categorization according to the plus code
The instructions, technical data and dimensional drawings which concern only
certain optional selections are marked with plus codes, e.g. +E210 or +H354. The
options included in the drive can be identified from the plus codes visible on the type
designation label of the drive. The plus code selections are listed in chapter The
ACS800-04/U4 and ACS800-04M under Type code.
Contents
The chapters of this manual are briefly described below.
About this manual introduces this manual.
The ACS800-04/U4 and ACS800-04M describes the drive module.
Planning the cabinet installation instructs on general cabinet design, gives layout
examples, free space requirements around the drive module for cooling and cabinet
cooling data.
Mechanical installation of pre-assembled units (ACS800-04/U4) instructs how to
mount a pre-assembled drive module into a cabinet.
Mechanical installation of non-pre-assembled units (ACS800-04M) instructs how to
assemble the drive from the assembly kits.
Checking the installation helps in checking the mechanical and electrical installation
of the drive.
Dimensional drawings contains the dimensional drawings of the drive modules.
Circuit diagrams shows an example circuit diagram for employing the Prevention of
Unexpected Start function (+Q950).
Assembly drawings contains a few step-by-step assembly drawings.
About this manual
13
Installation, commissioning and operating flowchart
Task
Chapters in this manual
Chapters in ACS800-04/04M/U4
Hardware Manual
[3AFE64671006 (English)]
Identify the frame size of your drive, R7 or R8. -
Technical data / IEC ratings or
NEMA ratings
Plan the installation.
Planning the cabinet installation
Technical data
Check the ambient conditions, ratings,
required cooling air flow, input power
connection, compatibility of the motor, motor
connection, and other technical data.
If optional equipment is included, see
its manuals.
Planning the electrical installation
Unpack and check the units.
Mechanical installation of preassembled units (ACS800-04/U4) or
Mechanical installation of non-preassembled units (ACS800-04M)
-
Check that all necessary optional modules
and equipment are present and correct.
Only intact units may be started up.
If the converter has been nonoperational for more than one year,
the converter DC link capacitors need
to be reformed. Ask ABB for
instructions.
Assemble and install the drive module into the Mechanical installation of precabinet.
assembled units (ACS800-04/U4) or
Mechanical installation of non-preassembled units (ACS800-04M)
Install the RDCU drive control unit.
-
See RDCU Drive Control Unit
Hardware Manual
[3AFE64636324 (English)]
Check the installation.
Checking the installation
-
Electrical installation
-
Safety, Planning the electrical
installation, Electrical installation,
Maintenance, Technical Data,
Resistor braking
Commissioning and operating the drive
-
See the appropriate firmware
manual.
About this manual
14
Product and service inquiries
Address any inquiries about the product to your local ABB representative, quoting
the type code and serial number of the unit in question. A listing of ABB sales,
support and service contacts can be found by navigating to www.abb.com/drives and
selecting Drives – World wide service contacts on the right pane.
Product training
For information on ABB product training, navigate to www.abb.com/drives and select
Drives – Training courses on the right pane.
Providing feedback on ABB Drives manuals
Your comments on our manuals are welcome. Go to www.abb.com/drives, then
select successively Drives – Document Library – Manuals feedback form on the right
pane.
About this manual
15
The ACS800-04/U4 and ACS800-04M
What this chapter contains
This chapter describes the construction and operating principle of the drive in short.
The ACS800-04/U4
The ACS800-04/U4 is an IP 00 drive module for controlling AC motors. It is to be
installed into a cabinet by the customer with base or wall fastening. The input cable
terminals are located at the top of the unit whereas the motor cable terminals are
located at the left- or right-hand side of the unit. The unit is delivered pre-assembled
with mounting pedestal and output busbars.
Slots for cables going to the RMIO board in the RDCU unit. The cables are coiled
on the top of the module.
Fastening points
Input cable terminals
Fastening points
Terminal block for user connection
of optional Prevention of
Unexpected Start (+Q950). See
ACS800-04/04M/U4 Cabinet
Installation [3AFE68360323
(English)] chapter Circuit diagrams.
Fastening points
Front cover
Motor cable terminals
Drive Control Unit
(RDCU)
Optional brake and DC
busbars and terminals
PE terminal
Alternative output cable
terminals (when no
vertical busbars are used)
Additional holes for fastening the cable
terminals
Pedestal
Fastening bracket
The ACS800-04/U4 and ACS800-04M
16
The ACS800-04M
The ACS800-04M is delivered as non-pre-assembled kits, which provide more
alternatives in assembling the units than the basic ACS800-04.
Example configurations
Frame size R7
Motor and brake busbars on the
left-hand long side of the module
and DC busbars on the right-hand
side
Motor and brake busbars on the
right-hand long side of the module
and DC busbars on the left-hand
side
Frame size R8
Drive Control Unit
(RDCU)
Frame size R7 with bottom exit
(optional top entry busbar
shroud and bottom exit shroud
included). Output busbars are
located at the base of the
module.
Output busbars on the short
side of the module
The ACS800-04/U4 and ACS800-04M
Output busbars on the short
side of the module
17
Type designation label
The type designation label includes an IEC and NEMA rating, C-UL US, and CSA
markings, a type code and a serial number, which allow individual recognition of
each unit. 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 with the
same serial number.
The type designation label is located on the front cover and the serial number label
inside the unit. Example labels are shown below.
The ACS800-04/U4 and ACS800-04M
18
Type code
The type code contains information on the specifications and configuration of the
drive. The first digits from left express the basic configuration (e.g. ACS800-040170-5). The optional selections are given thereafter, separated by plus signs (e.g.
+E202). The main selections are described below. Not all selections are available for
all types. For more information, refer to ACS800 Ordering Information (EN code:
64556568, available on request).
Type code for ACS800-04 and ACS800-U4 pre-assembled units
Alternatives
ACS800 product series
04
Drive module. When no options are selected: 6-pulse diode input bridge, IP 00, top
entry, side exit, RDCU drive control unit, no control panel, no EMC filter, Standard
Control Program, boards without coating, pedestal with output on the long side, output
busbar set for motor, base and wall mounting brackets, one set of manuals. Preassembled unit.
U4
Drive module (USA). When no options are selected: 6-pulse diode bridge, open
chassis, top entry, side exit, no control panel, no EMC filter, US version of the
Standard Control Program (three-wire start/stop as default setting), common mode
filter in frame size R8, boards without coating, pedestal with output on the long side,
output busbar set for motor, base and wall mounting brackets, one set of manuals.
Pre-assembled unit.
Size
Refer to Technical data: IEC ratings or NEMA ratings in Hardware Manual [3AFE64671006
(English)].
Voltage range
2
208/220/230/240 VAC
(nominal rating in bold) 3
380/400/415 VAC
5
380/400/415/440/460/480/500 VAC
7
525/575/600/690 VAC
+ options
Resistor braking
D150 brake chopper and busbars for brake resistor and DC connection
Filter
E210 EMC/RFI filter for second environment TN/IT (grounded/ungrounded) system
E208 common mode filter
Pedestal and output
0H354 no pedestal
busbars
Control panel
J400 control panel including a 3-metre panel connection cable
J410 RPMP-11 control panel mounting platform kit including a 3-metre panel connection
cable but no control panel
J413 RPMP-21 control panel holder
Fieldbus
K...
Refer to ACS800 Ordering Information (EN code: 64556568).
I/O
L...
Control program
N...
Language of manual
R...
Specialities
P901 coated boards
Safety features
Q950 Prevention of Unexpected Start, 500 mm (19.68 in.) cable outside the drive module in
frame size R7, 600 mm (23.62 in.) cable outside the drive module in frame size R8.
Selection
Product series
Type
The ACS800-04/U4 and ACS800-04M
19
Type code for ACS800-04M non-pre-assembled units (delivered as kits)
Alternatives
ACS800 product series
04M Drive module. When no options are selected: 6-pulse diode input bridge, IP 00, top
entry, RDCU drive control unit, Standard Control Program, boards without coating,
one set of manuals. No pedestal, no output busbars, no control panel, no EMC filter.
Delivered as kits.
Size
Refer to Technical data: IEC ratings in Hardware Manual [3AFE64671006 (English)].
Voltage range
2
208/220/230/240 VAC
(nominal rating in bold)
3
380/400/415 VAC
5
380/400/415/440/460/480/500 VAC
7
525/575/600/690 VAC
+ options
Shrouds
B060 Frame size R7: clear plastic shrouds for bottom exit kit (+H352) and input terminals.
Frame size R8: clear plastic shrouds for vertical busbars and input terminals in
bookshelf mounting (+H354)
Resistor braking
D150 brake chopper
Filter
E202 EMC/RFI filter for first environment TN (grounded) system, restricted (the A limits)
E210 EMC/RFI filter for second environment TN/IT (grounded/ungrounded) system
E208 common mode filter
Pedestal and output
H352 bottom exit kit for frame size R7
busbars
H354 pedestal with output on the long side (bookshelf)
H355 vertical busbars and support brackets for AC output connection
H356 pedestal (and adapter with +H360) busbar kit for brake resistor and DC connection
H360 pedestal with output on the short side (flat)
H362 vertical busbars (and support brackets with +H360) for DC output connection
H363 busbar kit for DC and brake outputs on different long sides of the pedestal (+H356
required, not available for +H360)
Control panel
J400 control panel including a 3-metre panel connection cable
J410 RPMP-11 control panel mounting platform kit including a 3-metre panel connection
cable but no control panel
J413 RPMP-21 control panel holder
Fieldbus
K...
Refer to ACS800 Ordering Information (EN code: 64556568).
I/O
L...
Control program
N...
Language of manual
R...
Specialities
P901 coated boards
Safety features
Q950 Prevention of Unexpected Start, 500 mm (19.68 in.) cable outside the drive module in
frame size R7, 600 mm (23.62 in.) cable outside the drive module in frame size R8.
Selection
Product series
Type
The ACS800-04/U4 and ACS800-04M
20
Main circuit and control interfaces
This diagram shows the control interfaces and the main circuit of the drive.
Motor
control and
I/O board
(RMIO)
Optional module 1: RMBA, RAIO,
RDIO, RDNA, RLON, RIBA, RPBA,
RCAN, RCNA, RMBP, RETA, RRIA or
RTAC
Optional module 2: RTAC, RAIO, RRIA
or RDIO
External control via
analogue/digital
inputs and outputs
DDCS communication option module:
RDCO-01, RDCO-02 or RDCO-03
Drive
Capacitor bank
U1
Rectifier
Inverter
U2
AC supply V1
W1
V2 Motor output
W2
Brake chopper
(optional)
R- UDC+ UDCR+
The ACS800-04/U4 and ACS800-04M
21
Connections of the Drive Control Unit (RDCU) in frame sizes R7 and R8
ACS800-04
drive module
Protective tube
AINT
3 m (118 in.)
80 (3.1
5”)
ø 4.5 (0.18”)
80 (3.15”)
Shield
APOW
2100 mm (83 in.)
Shielded 6-pin
modular connector
To RMIO
Control panel mounting platform
kit (RPMP-11, optional)
3 m (118 in.)
External control connections
to RMIO board
Drive control unit
RDCU which
contains motor
control and I/O
board RMIO
Control panel
CDP312R (optional)
Operation
This table describes the operation of the main circuit in short.
Component
Description
six-pulse rectifier
converts the three-phase AC voltage to DC voltage
capacitor bank
energy storage which stabilizes the intermediate circuit DC voltage
six-pulse IGBT inverter
converts the DC voltage to AC voltage and vice versa. The motor
operation is controlled by switching the IGBTs.
The ACS800-04/U4 and ACS800-04M
22
Printed circuit boards
The drive contains the following printed circuit boards as standard:
• main circuit board (AINT)
• motor control and I/O board (RMIO) with a fibre optic link to the AINT board
• input bridge control board (AINP)
• input bridge protection board (AIBP) which includes snubbers for the thyristors
and varistors
• power supply board (APOW)
• gate driver control board (AGDR)
• diagnostics and panel interface board (ADPI)
• brake chopper control board (ABRC) with option +D150
Motor control
The motor control is based on the Direct Torque Control (DTC) method. Two phase
currents and DC link voltage are measured and used for the control. The third phase
current is measured for earth fault protection.
The ACS800-04/U4 and ACS800-04M
23
Planning the cabinet installation
What this chapter contains
This chapter guides in planning the installation of a converter module into a userdefined cabinet. The chapter gives free space requirements around the module for
cooling, cabinet cooling data and layout examples. The issues discussed are
essential for the safe and trouble-free use of the drive system.
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.
Cabinet construction
The cabinet frame must be sturdy enough to carry the weight of the drive
components, control circuitry and other equipment installed in it.
The cabinet must protect the converter module against contact and meet the
requirements for dust and humidity, see chapter Technical data in ACS800-04/04M/
U4 Hardware Manual [3AFE64671006 (English)].
Disposition of the devices
For easy installation and maintenance, a spacious layout is recommended. Sufficient
cooling air flow, obligatory clearances, cables and cable support structures all
require space.
The control boards must not be installed near main circuits or hot parts.
The following sections show a few layout examples. For example layouts in
Rittal TS 8 cabinet, refer to ACS800-04/U4 Rittal TS 8 Cabinet Installation
[3AFE68372330 (English)].
Planning the cabinet installation
24
Layout examples, door closed
IP 22
IP 54
2c
2b
2a
3
3
4
4
5
5
1a
1b
2a
2b
2c
3
4
1a
1a
5
1a
1a
1b
1b
Roof air flow viewed from top
Planning the cabinet installation
Air inlet for the converter module
Air inlet for the other equipment
Air outlet for the converter module
Air outlet for the other equipment
Air outlet for the converter module and the
other equipment, an extra exhaust fan
Converter control panel (connected to the
RMIO board in the RDCU unit inside the
cabinet)
Contactor control switch and emergency
stop switch (connected to the contactor
control circuit inside the cabinet)
Operating handle of the disconnector
25
Layout examples, door open
IP 54
IP 22
1
1
3
3
n
n
5
3
8
5
2
6
3
8
4
n
2
6
4
n
3
9
3
1 Supporting frame of the cabinet
2 Air baffles that separate the cool and hot
areas (leak-proof lead-throughs)
3 Input power cable including the protective
conductors to cabinet grounding (PE)
4 Disconnector and fuses
5 Contactor
6 Converter module
7 Motor cable including the grounding
conductors
8 Drive Control Unit RDCU (includes RMIO
board)
9 External control cables
9
PE
3
7
PE
3
7
Air flow to the roof
IP 22
Air flow through the module
IP 54
Fan
2
2
See also section Required free space around the drive
module for cooling.
WARNING! For units without bottom exit kit (+H352), it is not allowed to connect the
cables directly to the drive module terminals without the pedestal as the leadthrough insulation material is not strong enough to carry the mechanical stress
exerted by the cables.
Planning the cabinet installation
26
Grounding of mounting structures
Make sure any cross-members or shelves on which components are mounted are
properly grounded and the connecting surfaces left unpainted. The drive module will
be grounded to the cabinet frame via its fastening screws.
Busbar material and joints
Tin-plated copper is recommended but aluminium can also be used.
Before joining aluminium busbars, remove the oxide layer and apply suitable antioxidant joint compound.
Tightening torques
The following table applies to grade 8.8 screws (with or without joint compound).
Screw size
Torque
M5
3.5 N·m (2.6 lbf·ft)
M6
9 N·m (6.6 lbf·ft)
M8
20 N·m (14.8 lbf·ft)
M10
40 N·m (29.5 lbf·ft)
M12
70 N·m (52 lbf·ft)
M16
180 N·m (133 lbf·ft)
Cabinet cooling
The installation site must be sufficiently ventilated.
The cabinet must have enough free space for the components to ensure sufficient
cooling. Observe the minimum clearances given for each component.
The heat dissipated by cables and other additional equipment must also be
ventilated.
The air inlets and outlets must be equipped with gratings that
• guide the air flow
• protect against contact
• prevent water splashes from entering the cabinet.
Planning the cabinet installation
27
The drawing below shows two typical cabinet cooling solutions. The air inlet is at the
bottom of the cabinet, while the outlet is at the top, either on the upper part of the
door or on the roof.
Air outlet
Air inlet
The internal cooling fans of the converter modules and reactors/chokes are usually
sufficient to keep the component temperatures low enough in IP 22 cabinets.
In IP 54 cabinets, thick filter mats are used to prevent water splashes from entering
the cabinet. This entails the installation of additional cooling equipment, such as a
hot air exhaust fan.
Arrange the cooling air flow through the converter module so that the requirements
given in chapter Technical data in ACS800-04/04M/U4 Hardware Manual
[3AFE64671006 (English)] are met:
• cooling air flow
Note: The figures apply to continuous nominal load. If the load is cyclic or less than nominal, less
cooling air is required.
• allowed ambient temperature.
See section Cabinet cooling data for:
• allowed temperature rise inside the cabinet
• allowed pressure drop over the cabinet that the module fan can overcome
• air inlet and outlet sizes required for the module cooling and recommended filter
material (if used).
Planning the cabinet installation
28
Cabinet cooling data
IP 22 cabinet with no extra fan
The table below shows the data the IP 22 cabinet should meet to ensure efficient
cooling of the converter module. No extra fan is used. The pressure drop over the
cabinet is the additional counterpressure that the module fan is capable of
overcoming while still maintaining the required air flow through the module.
Frame
size
R7
R8
Temp. rise
Over module
°C
30
30
Pressure drop
Cabinet air inlet
Over module Over cabinet
Min. size
Filter
Pa
Pa
mm
by Luftfilter
300
30
288×292+688×521
airTex G150
300
45
288×292+688×521
airTex G150
Min. cabinet air
outlet size*
mm
398×312 (2 pcs)
398×312 (2 pcs)
00096931
* size when the outlet is located on the cabinet roof
IP 54 cabinet with an extra fan
The table below shows the data the IP 54 cabinet should meet to ensure efficient
cooling of the converter module. An extra fan is used. The pressure drop over the
cabinet is the counterpressure the extra fan must overcome. The given fan types
and filter materials are examples. Corresponding products by another manufacturer
may be used as well. See the manufacturer’s Internet site for the detailed
specification.
Frame
Size
R7
Temp. rise
Over module
°C
30
R8
30
Pressure drop
Extra fan type
Air inlet and outlet filter by Luftfilter
Over cabinet
Min. inlet (door)
Min. outlet (roof)
Pa
mm
mm
250*
RB2C-225/088 K093 or airComp 300-50
airTex G150
R2E225-AU64 by ebm 288×292 + 688×521
398×312 (2 pcs)
250*
RH35M-4EK.2F.1R by airComp 300-50
airTex G150
Ziehl-Abegg or RB4T- 288×292 + 688×521
398×312 (2 pcs)
355/170 by ebm
00096931
* inlet filter 50 % unclean
Planning the cabinet installation
29
Preventing the recirculation of hot air
Converter cubicle from side
Converter cubicle from above
A-A
Vertical air baffle
Air flow out
A
A
Converter
module
Horizontal air baffle
Converter
module
Air flow in max. 40°C (104 °F)
Outside the cabinet
Prevent hot air circulation outside the cabinet by leading the outcoming hot air away
from the area where the inlet air to the cabinet is taken. Possible solutions are listed
below:
• gratings that guide air flow at the air inlet and outlet
• air inlet and outlet at different sides of the cabinet
• cool air inlet in the lower part of the front door, and an extra exhaust fan on the
roof of the cabinet.
Inside the cabinet
Prevent hot air circulation inside the cabinet with e.g. leak-proof air baffles at the
positions shown in the diagrams in section Required free space around the drive
module for cooling. No gaskets are usually required.
Cubicle heaters
Use a cubicle heater if there is a risk of condensation in the cabinet. Although the
primary function of the heater is to keep the air dry, it may also be required for
heating at low temperatures. When placing the heater, follow the instructions
provided by its manufacturer.
Planning the cabinet installation
30
Required free space around the drive module for cooling
Free space at the top of the drive module
Required free space at the top of the module for frame sizes R7 and R8 is shown
below (views of frame size R7). Note: Air inlet gratings only at the lower part of the
cabinet door are not recommended without an extra fan. The air baffles are
examples.
Air outlet on the cabinet roof and
high air inlet gratings in the cabinet
door
Air outlet and high air inlet gratings in
the cabinet door
200 mm
(7.87 in.)
300 mm
(11.81 in.)
Air baffles
not required if the
drive module
touches the
cabinet door
Bookshelf
Flat
Bookshelf
Flat
See also pages 31 and 32.
Air outlet and low air inlet gratings in the
cabinet door
Air outlet on the cabinet roof and low
air inlet gratings in the cabinet door
300 mm
(11.81 in.)
200 mm
(7.87 in.)
Air baffles
Bookshelf
See also pages 31 and 32.
Planning the cabinet installation
Bookshelf
31
Free space around units with busbars on the long side (bookshelf mounting
+H354)
The figure below shows the required free space in a unit with motor and brake
busbars connected to the left-hand side and DC busbars to the right-hand side of the
module (+H354+H356+H362+H363). The required free space when no vertical
busbars are used is also shown.
100 mm (3.94 in.)
At the back no extra space is needed.
Cables connected to the output
busbars of the pedestal require
100 mm (3.94 in.) free space
around the busbars for cooling.
100 mm (3.94 in.)
50 mm (1.97 in.)
50 mm (1.97 in.)
0 mm (0 in.)
150 mm (5.91 in.)
Air inlet side
Cables connected
to the vertical
output busbar
terminals require
50 mm (1.97 in.)
free space around
the busbar
terminals for
cooling.
The required free space in front of the unit depends on the gratings in the cabinet
door:
• 0 mm (0 in.) with air inlets as high as the grating in the module [R7: 675 mm
(27 in.), R8: 1120 mm (44 in.)]
• 150 mm (5.91 in.) with air inlets at the lower part of the cabinet only.
Planning the cabinet installation
32
Free space around units with busbars on the short side (flat mounting +H360)
The required free space at the
air inlet side of the drive
module:
• 0 mm (0 in.) if cabinet
gratings are located at the air
inlet side of the drive module
and are as high as the grating
in the module [R7: 675 mm
(27 in.), R8: 1120 mm
(44 in.)]
• 150 mm (5.91 in.) with air
inlets at the lower part of the
cabinet only or with cabinet
gratings at the long side of
the drive module only.
Cables connected to the vertical
output busbar terminals require
50 mm (1.97 in.) free space around
the busbar terminals for cooling.
0 mm (0 in.)
50 mm (1.97 in.)
Air inlet side of the
drive module
100 mm (3.94 in.)
Cables connected to the output busbars of the
pedestal require 100 mm (3.94 in.) free space
around the busbars for cooling.
Location of air inlet gratings
Air inlet gratings in the cabinet are recommended at the air
inlet side of the drive module if free space in front of the
long side of the module is less than 150 mm (5.91 in.). The
required area of the gratings is approximately
3 × 300 mm × 300 mm (3 × 11.81 in. × 11.81 in.), the
minimum area is given on page 28.
If < 150 mm
(5.91 in.)
Door
Air baffle. Not needed if the drive module touches the
cabinet door or the module air inlet touches the air inlet
grating of the cabinet.
If > 150 mm
(5.91 in.)
Required area of air inlet gratings is approximately
3 × 300 mm × 300 mm (3 × 11.81 in. × 11.81 in.)
Planning the cabinet installation
33
When the drive module is installed in another position than vertically
• Fasten the drive module by the fastening points.
• Lay support brackets below the module to carry the module weight.
• Ensure that hot air flows freely out of the cabinet and does not build up pressure.
• Reserve enough space for the cabling.
• In case of a short-circuit inside the drive module, hot ionized gases may escape
sideways/upwards from the module through its ventilation holes. Ensure that the
cabinet is constructed so that this will not cause any danger.
• The outlet cooling air is 25...30 °C (77...86 °F) hotter than the inlet air and flows
sideways. Ensure that this does not cause danger.
• Ensure that the front panel, and preferably also the profiled side panel, can be
removed and the cooling fan and capacitor pack changed.
• Ensure that the module can be changed, e.g. by sliding out of the cabinet on rails.
Drive module of frame size R7 on its side
Air baffle for
preventing cooling
air recirculation
Prevent dripping water from
entering the drive module.
WARNING! Do not place the
support brackets under the studs.
They cannot carry the weight of
the drive module and the drive
module would deform when
placed onto them. The studs can
be sawn off.
Note: Air inlet into the drive module
goes through the front gratings of
the module. Do not cover them.
Leave space in front of the
module for maintenance.
Support the module from below.
The fastening points are not
sturdy enough to carry the
weight of the module when laid
on its side.
Ensure that the cooling
air will flow freely and is
clean. Use filter mats if
the input cooling air is
taken near the floor
surface and contains
dust.
Place the support brackets on
the same level as the spacers of
the back plate of the bottom exit
kit.
64796003_bottom_exit_copy<64796003>.asm
Planning the cabinet installation
34
Drive module of frame size R7 on its back
Prevent dripping water from
entering the drive module.
Ensure that the cooling air will flow freely and
is clean. Use filter mats if the input cooling air
is taken near the floor surface and contains
dust.
Note: Air inlet into the drive module
goes through the front gratings of
the module. Do not cover them.
Leave space above the module
for maintenance
Air baffle for preventing cooling
air recirculation
Support the module from below.
The fastening points are not
sturdy enough to carry the
weight of the module when laid
on its back.
64796003_bottom_exit_copy<64796003>.asm
Planning the cabinet installation
35
EMC requirements
Generally, the fewer and smaller the holes in the cabinet, the better the interference
attenuation. The maximum recommended diameter of a hole in galvanic metal
contact in the covering cabinet structure is 100 mm. Special attention must be paid
to the cooling air inlet and outlet gratings.
The best galvanic connection between the steel panels is achieved by welding them
together as no holes are necessary. If welding is not possible, the seams between
the panels are recommended to be left unpainted and equipped with special
conductive EMC strips to provide adequate galvanic connection. Usually, reliable
strips are made of flexible silicon mass covered with a metal mesh. The nontightened touch-contact of the metal surfaces is not sufficient, so a conductive
gasket between the surfaces is required. The maximum recommended distance
between assembly screws is 100 mm.
Sufficient high-frequency grounding network must be constructed in the cabinet to
avoid voltage differences and forming of high-impedance radiator structures. A good
high-frequency grounding is made with short flat copper braids for low inductance.
One-point high-frequency grounding cannot be used due to the long distances inside
the cabinet.
First environment EMC compliance *) of the drive requires 360° high frequency
grounding of the motor cable shields at their entries. The grounding can be
implemented by a knitted wire mesh screening as shown below.
Bare cable shield
Cable ties
Knitted wire mesh
Lead-through plate
Cable
Cabinet bottom plate
*) First environment EMC compliance is defined in chapter Technical data / CE marking in ACS800-04/
04M/U4 Hardware Manual [64671006 (English)].
Planning the cabinet installation
36
360° high frequency grounding of the control cable shields is recommended at their
entries. The shields can be grounded by means of conductive shielding cushions
pressed against the cable shield from both directions:
Bare cable shield
Shielding cushion
(conductive)
Cabinet bottom plate
Cable
Cable grommet
Grounding of cable shields
To power terminals
Example cable lead-through
Strain relief
Cable shield
PE terminal of the
cabinet or drive module
EMC sleeve *
Strip this part of
the cable
Recommended for
control cables
Base plate
Lead-through plate
* required for motor cables in first environment installations. First environment EMC compliance is
defined in chapter Technical data / CE marking in ACS800-04/04M/U4 Hardware Manual [64671006
(English)].
Installing the Drive Control Unit (RDCU)
See RDCU Drive Control Unit Hardware Manual [3AFE64636324 (English)].
Planning the cabinet installation
37
Fastening of the control panel (CDP312R)
The control panel can be fastened directly to the cabinet door, or a mounting
platform or control panel holder (+J413) can be used.
Installing the control panel directly on the cabinet door
Fasten the control panel from the back side with two screws of one of the following
types:
• standard screw with nominal diameter of 4 mm (0.16 in.)
• tapping screw with nominal diameter of 4.2 mm (0.17 in.) DIN 7981 C,
DIN 7982 C, DIN 7983 C or DIN 7976 C
• PT screw for thermoplastics with nominal diameter of 4 mm (0.16 in.).
View from outside the cabinet door
Control panel
Cabinet door
Tightening torque:
1 Nm (0.74 lbf ft)
10 mm (0.39 in.)
Control panel footprint
4...8 mm
(0.16...0.31 in.)
Control Panel Mounting Platform RPMP-11/13 (+J410)
For installation of the mounting platform, see RPMP-11/13 Control Panel Mounting
Platform Kit Installation Guide [3AFE68400643 (English)].
Planning the cabinet installation
38
Control Panel Holder RPMP-21 (+J413)
Fasten the control panel holder to the cabinet frame or wall with three screws. Do not
fasten the panel holder to the drive module.
Planning the cabinet installation
39
Mechanical installation of pre-assembled units
(ACS800-04/U4)
What this chapter contains
This chapter describes how to install a pre-assembled drive module into a cabinet.
First, before-installation information is given, such as required tools, moving the unit
and checking the delivery. Then, the mechanical installation procedure is described.
Moving and unpacking the unit
WARNING! The drive is heavy [frame size R7: 100 kg (220 lb), frame size R8:
200 kg (441 lb)]. Lift the drive by the upper part only using the lifting lugs attached to
the top of the unit. The lower part will be deformed from lifting. Do not remove the
pedestal before lifting.
M ax
30°
Do not tilt the drive. The centre of gravity of the unit is high. The unit will overturn
from a tilt of about 6 degrees. An overturning unit can cause physical injury.
Views of frame size R7
Do not lift by the lower
part of the frame.
Do not tilt!
Mechanical installation of pre-assembled units (ACS800-04/U4)
40
Move the transport package by pallet truck to the installation site. Unpack the
package as shown below.
Undo the
fastening
screws.
The following items are located below the drive
module:
The following items are fastened to
the drive module:
Drive Control Unit (RDCU)
Note: Optional modules (if ordered) are
factory installed onto the RMIO board in
the RDCU unit. The fibre optic cables and
power supply cable to be connected to the
RMIO board are coiled on the top of the
drive module.
• pedestal
• output busbars U2, V2 and W2
• busbars for brake resistor
connection if brake chopper is
included.
• DC busbars if ordered
Base and wall fastening brackets,
terminals for output cable connection
and PE grounding. Screws are included
in a plastic bag.
Control panel with a 3 m (98 in.) cable
and RPMP control panel mounting kit (if
ordered)
Manuals (hardware, appropriate firmware,
optional module), delivery documents,
residual voltage warning stickers
Delivery check
Check that there are no signs of damage. Before attempting installation and
operation, check the information on the type designation label of the drive to verify
that the unit is of the correct type.
Mechanical installation of pre-assembled units (ACS800-04/U4)
41
Required tools
• set of screw drivers
• torque wrench with a 500 mm (20 in.) or 2 × 250 mm (2 × 10 in.) long extension
bar
• 19 mm (3/4 in.) socket
for frame size R7: 13 mm (1/2 in.) magnetic-end socket
for frame size R8: 17 mm (11/16 in.) magnetic-end socket.
Mechanical installation of pre-assembled units (ACS800-04/U4)
42
Installation procedure
Fasten the module to the cabinet
Fasten the module to the base of the cabinet with the outside fastening brackets as
described below. For instructions in alternative fastening methods, refer to
Mechanical installation of non-pre-assembled units (ACS800-04M).
It is recommended to fasten the module also from the fastening points at the top of
the unit. Refer to Dimensional drawings for the horizontal and vertical fastening
points.
Clamping the pedestal with the outside brackets
1. Fasten the front bracket to the pedestal with two screws.
2. Fasten the back fastening bracket onto the cabinet floor with two screws.
3. Place the pedestal on the cabinet floor and push it so that the tabs of the
fastening bracket enter the slots in the pedestal.
4. Fasten the front bracket to the base with two screws.
2
2
3
1
M8
M8 (5/16 in.)
4
4
Tightening torque: 5 Nm (3.7 lbf ft)
Note: Place the module on a solid base. The fastening brackets are not strong
enough to carry the weight of the module on their own.
Fasten the terminals to the busbars
1. Connect the PE terminal to the long side plate of the pedestal with screws.
2. Connect the output cable terminals to the busbars with screws.
Note 1: The output cable terminals and PE terminal need not necessarily be used.
The output cables can be also connected directly to the vertical output busbar holes
with cable lugs. The PE conductors can be connected to the PE terminal screws.
Busbars for output cables can be connected to the pedestal busbars.
Mechanical installation of pre-assembled units (ACS800-04/U4)
43
View of output busbar connections of frame size R7 (DC and brake busbars included)
Top view of insulating support and cable
lug terminal connections
Insulating support
M8x16
M8x20
M10x25
Cable lug
terminal
WARNING! The output busbars are fastened to the insulating supports with M8x16 screws
when no cable lug terminal is connected, but with M8x20 screws when a cable lug terminal
is also connected with the same screw. Screwing an M8x20 screw without a cable lug
terminal through the busbar into the insulating support will break the insulating support.
Fasten the cable lug terminals elsewhere with M10x25 screws.
2
2
2
2
2
2
Tightening torques
M8: 15...22 Nm (3.7 lbf ft)
2
2
2
2
M10: 30...44 Nm (22...32 lbf ft)
2
2
R-
Nut
M10x30
Spring washer with
mechanically sprayed zinc
coating
Plain washer with
electroplated zinc coating
and yellow chromate
passivation
Tightened at the factory
M8
1
Mechanical installation of pre-assembled units (ACS800-04/U4)
44
View of output busbar connections of frame size R8 (DC and brake busbars included)
WARNING! Fasten the output busbars to the insulating supports with M10x20
screws when no cable lug terminal is connected, but with M10x25 screws when a
cable lug terminal is connected as well. Screwing an M10x25 screw without a
cable lug terminal through the busbar into the insulating support will break the
insulating support.
M10x25
M10x20
M10x25
2
2
2
2
2
2
2
2
R-
UDC+
2
2
2
2
W2
V2
U2
R+
UDC-
M10
2 pcs
Nut
1
Tightening torque
M10: 30...44 Nm (22...32 lbf ft)
M12: 50...75 Nm (37...55 lbf ft)
Plain washer with
electroplated zinc coating
and passivation
M12x35
Tightened at the factory
User connections of Prevention of Unexpected Start (+Q950)
See pages 72 and 97.
Mechanical installation of pre-assembled units (ACS800-04/U4)
Spring washer with
mechanically sprayed zinc
coating
45
Mechanical installation of non-pre-assembled units
(ACS800-04M)
What this chapter contains
This chapter describes how to assemble the drive from the assembly kits. First,
before-installation information is given, such as required tools, moving the unit and
checking the delivery. Then, the working order of the mechanical installation is
described. Thereafter, particular assembling instructions follow.
How to read this chapter
Units with bottom exit
1. Read sections Required tools and tightening torques and Moving and unpacking
the unit.
2. Go to section Frame size R7 units with bottom exit (+H352) on page 49.
Units with pedestal and busbars on the long side (+H354, bookshelf mounting)
1. Read sections Required tools and tightening torques and Moving and unpacking
the unit.
2. Identify your unit by its type code with the help of section Units with pedestal and
busbars on the long side (+H354, bookshelf mounting) on page 57.
3. Choose the applying instructions in section Assembling procedure for units with
busbars on the long side (+H354) on page 73.
Units with pedestal and busbars on the short side (+H360, flat mounting)
1. Read sections Required tools and tightening torques and Moving and unpacking
the unit.
2. Identify your unit by its type code with the help of section Units with pedestal and
busbars on the short side (+H360, flat mounting) on page 91.
3. Choose the applying instructions in section Assembling procedure for units with
busbars on the short side (+H360) on page 104.
Mechanical installation of non-pre-assembled units (ACS800-04M)
46
Required tools and tightening torques
• set of screw drivers
• torque wrench with a 500 mm (20 in.) or 2 x 250 mm (2 x 10 in.) long extension
bar
• 19 mm (3/4 in.) socket
for frame size R7: 13 mm (1/2 in.) magnetic-end socket
for frame size R8: 17 mm (11/16 in.) magnetic-end socket.
Screw
M4
M5
M6
M8
M10
M12
Grade
8.8
8.8
8.8
8.8
8.8
8.8
Tool
mm
7
8
10
13
17
19
in.
5/16
3/8
1/2
Tightening torque
Nm
lbf ft
2
1.46
4
6...9
3.7
15...22
3.7
30...44
22...32
50...75
37...55
Moving and unpacking the unit
Max
3
0°
WARNING! The drive is heavy [frame size R7: 100 kg (220 lb), frame size R8:
200 kg (441 lb)]. Lift the drive using the lifting lugs attached to the top of the unit. Do
not tilt the drive. The centre of gravity of the unit is high. The unit will overturn
from a tilt of about 6 degrees. An overturning unit can cause physical injury.
Do not tilt!
Mechanical installation of non-pre-assembled units (ACS800-04M)
47
The module is delivered in a two-level package. Unpack the package as shown
below.
Move the transport package by pallet truck to the installation site. Lift up the
top cover. The following items are located in the upper package (1):
• pedestal
• output busbars U2, V2 and W2
• supports, screws and terminals for the output busbars and PE grounding
• fastening brackets for base and wall mounting
• busbars for brake resistor connection (if brake chopper is ordered)
• adapter (if output busbars on the short side of the module)
1
• DC busbars (if ordered)
• control panel and a 3 m (98 in.) cable (if ordered)
• control panel mounting platform (if ordered).
In the lower package (2):
• drive module.
Below the drive module (3):
• Drive Control Unit (RDCU). Note: The fibre optic cables and power supply
cable to be connected to the RMIO board inside the RDCU unit are wound
on the top of the drive module.
• optional modules (if ordered) factory installed onto the RMIO board in the
RDCU unit
2
• residual voltage warning and output busbar stickers
• hardware manual
• appropriate firmware manuals and guides
• delivery documents
• optional module manuals.
Top view
Bottom view
3
Undo the fastening
screws.
Mechanical installation of non-pre-assembled units (ACS800-04M)
48
Fasten the lifting hooks to the lifting
lugs of the drive module. A hook can
be fastened to the base bracket also.
Use at least three fastening points
because the module is turns over
easily.
Mechanical installation of non-pre-assembled units (ACS800-04M)
49
Frame size R7 units with bottom exit (+H352)
Delivery check
Check that there are no signs of damage. Before attempting installation and
operation, check the information on the type designation label of the drive to verify
that the unit is of the correct type.
ACS800-04M of frame size R7 with bottom exit
Parts
Assembling drawing / reference to instruction
Package
ProE code 64770306 D
Basic unit (type code ACS800-0M4-xxxx-x+H352)
Refer to section Assembling procedure on page 53.
Drive module
See RDCU Drive Control Unit Hardware Manual
[3AFE64636324 (English)].
RDCU drive control unit
(RDCU)
Drive control unit
-
Front
Mechanical installation of non-pre-assembled units (ACS800-04M)
50
ACS800-04M of frame size R7 with bottom exit
Parts
Assembling drawing / reference to instruction
Package
ProE code 64770306 D
68324963
Front
Bottom exit kit R7
+H352
L-plate
Spacers for wall mounting
R-busbar with
fastening pin
Bottom plate
Mechanical installation of non-pre-assembled units (ACS800-04M)
51
ACS800-04M of frame size R7 with bottom exit
Parts
Assembling drawing / reference to instruction
Package
ProE code 64770306 D
Top entry busbar shroud kit R7
+B060
Optional selection +H352+B060: top entry busbar shroud and bottom exit shroud
68363977
Bottom exit shroud kit R7
+B060
68339545
Screws
Mechanical installation of non-pre-assembled units (ACS800-04M)
52
Package
ACS800-04M of frame size R7 with bottom exit
Parts
Assembling drawing / reference to instruction
ProE code 64770306 D
Example assembly+H352+B060: bottom exit with top entry busbar shroud and bottom exit shroud
Top entry busbar shroud
kit (+B060)
Front
Bottom exit
kit (+H352)
Bottom exit shroud kit
(+B060)
Mechanical installation of non-pre-assembled units (ACS800-04M)
53
Assembling procedure
Assemble the units with bottom exit (+H352) as follows:
1. Remove the front cover of the drive module.
2. Fasten the L-plate to the base of the module.
A. Insert the two pins of the longer side of the L-plate to the counter holes in the side plate of the
drive module.
B. Slide the L-plate horizontally to match the three pins in its shorter side with the counter holes in
the drive module.
C. Fasten the L-plate with 5 screws.
1
B
C
C
C
C
C
A
Mechanical installation of non-pre-assembled units (ACS800-04M)
54
3. Fasten the bottom plate to the base of the drive module.
A. With brake chopper option (+D150), fasten R- busbar to the
bottom plate with pin A1.
B. Insert the bottom plate onto its place.
C. Connect the busbars of the bottom plate to the busbars of the
drive module with M8x25 combi screws using a torque wrench
with an extension bar. Tightening torque: 15...22 Nm
(11...16 lbf ft).
D. Fasten the bottom plate to the drive module with four M6
screws. Tightening torque: 6...9 Nm (3.7 lbf ft).
B
A1
A
C
C
C
C
C
D
R+/UDC+
U2 V2
UDCW2
C
4. Fasten the front cover.
Mechanical installation of non-pre-assembled units (ACS800-04M)
RD
D
55
Fastening the spacer
Fasten the the drive module to the cabinet or wall using a spacer at the top of the
module on the fastening side.
Fastening the spacer to the long side of the module
(flat mounting)
Fastening the spacer to the short side of the module
(bookshelf mounting)
Fastening the top entry busbar and bottom exit shrouds (+B060)
Top entry busbar shroud
5
Fasten the shroud to the drive module
5
4
5
5
Press the top cover on the
3
sides inwards to enable its tabs
to enter the slots in the shroud
when it is placed in position (4).
2
3
Remove the
protective film.
1 Step drill lead-throughs
for the busbars.
Mechanical installation of non-pre-assembled units (ACS800-04M)
56
Bottom exit shroud
4
Fasten the side plates to the
drive module.
Remove the protective film from all parts.
2
3
5
Fasten the bottom to
the shroud
Fasten the L-plate to
the drive module.
1 Step drill leadthroughs for the
busbars.
Mechanical installation of non-pre-assembled units (ACS800-04M)
57
Units with pedestal and busbars on the long side (+H354, bookshelf
mounting)
Delivery check
Check that there are no signs of damage. Before attempting installation and
operation, check the information on the type designation label of the drive to verify
that the unit is of the correct type.
Item packages
The following tables show what each item package contains:
• parts
• part list code
• plus code
• assembling instruction.
In the tables, the basic unit is described first, then the possible optional parts are
listed. Choose the table and options of your delivery in the following sections:
• Item packages of frame size R7 with busbars on the long side on page 58.
• Item packages of frame size R8 with busbars on the long side on page 64.
Note: The complete assembling instructions are represented under Assembling
procedure for units with busbars on the long side (+H354) on page 73.
Mechanical installation of non-pre-assembled units (ACS800-04M)
58
Item packages of frame size R7 with busbars on the long side
ACS800-04M of frame size R7 with busbars on the long side
Parts
Assembling drawing / reference to instruction
Package
ProE code 64770306 D
Basic unit (type code ACS800-0M4-xxxx-x+H354+H355)
Refer to section Assembling procedure for units with
busbars on the long side (+H354) on page 73.
Drive module
See RDCU Drive Control Unit Hardware Manual
[3AFE64636324 (English)].
RDCU drive control unit
(RDCU)
Drive control unit
-
Front
Mechanical installation of non-pre-assembled units (ACS800-04M)
59
ACS800-04M of frame size R7 with busbars on the long side
Parts
Assembling drawing / reference to instruction
Package
ProE code 64770306 D
Base mounting from outside:
Pedestal R7
+H354
64754416
Pedestal
64743309
left
right
Front
Wall mounting:
Base mounting brackets
+H354
Mounting bracket and grounding terminal kit R7
PE terminals
Wall mounting bracket
Spacer for wall mounting
Front
Mechanical installation of non-pre-assembled units (ACS800-04M)
60
ACS800-04M of frame size R7 with busbars on the long side
Parts
Assembling drawing / reference to instruction
Package
ProE code 64770306 D
64743180
Motor output busbar kit R7
+H355
Motor cable terminals
Insulating
supports
Support brackets
AC output busbars
Front
Control panel holder
+J413
Optional selection +J413: Control Panel Holder RPMP-21
68394961
Control panel holder
Mechanical installation of non-pre-assembled units (ACS800-04M)
61
ACS800-04M of frame size R7 with busbars on the long side
Parts
Assembling drawing / reference to instruction
Package
ProE code 64770306 D
Front
Pedestal busbars
+H356
Pedestal DC busbar kit R7
Optional selection +H354+H356+H362: DC/brake busbars
64769341
Insulating
supports
+H362
DC output busbar kit R7
64744747
Terminals
Side busbars
Front
Mechanical installation of non-pre-assembled units (ACS800-04M)
62
Package
ACS800-04M of frame size R7 with busbars on the long side
Parts
Assembling drawing / reference to instruction
ProE code 64770306 D
Bilateral DC output busbar kit R7
+H363
Optional selection +H354+H356+H362+H363: DC and brake busbars on opposite sides
64744895
DC busbars on the right side:
Long DC busbar for the
pedestal (ends on both
sides of the pedestal)
Front
DC busbars on the left side and brake busbars on
the right side:
Front
Mechanical installation of non-pre-assembled units (ACS800-04M)
63
ACS800-04M of frame size R7 with busbars on the long side
Parts
Assembling drawing / reference to instruction
Package
ProE code 64770306 D
Example assembly (+H354+H355+H356+H362+H363 included)
AC, brake and
DC busbars on
the left
Front
+H355
+H363
AC and brake busbars on the left and
DC busbars on the right
+H362
+H356
+H354
Mechanical installation of non-pre-assembled units (ACS800-04M)
64
Item packages of frame size R8 with busbars on the long side
ACS800-04M of frame size R8 with busbars on the long side
Package
Parts
Assembling instruction ProE code 64772023 E
Basic unit (type code ACS800-04M-xxxx-x+H354+H355)
Refer to section Assembling procedure for units with
busbars on the long side (+H354) on page 73.
Drive module
See RDCU Drive Control Unit Hardware Manual
[3AFE64636324 (English)].
RDCU drive control unit
(RDCU)
Drive control unit
-
Front
Mechanical installation of non-pre-assembled units (ACS800-04M)
65
Package
64754424
ACS800-04M of frame size R8 with busbars on the long side
Parts
Assembling instruction ProE code 64772023 E
Base mounting from outside:
Pedestal R8
+H354
Pedestal
64744330
terminal kit R8 (+H354)
Mounting bracket and grounding
left
Front
right
PE terminals
Wall mounting:
Wall mounting bracket
Base mounting
brackets
Front
64743295
Motor output busbar kit R8
+H355
Motor cable terminals
Insulating
supports
Support brackets
AC output busbars
Front
Mechanical installation of non-pre-assembled units (ACS800-04M)
66
ACS800-04M of frame size R8 with busbars on the long side
Package
Parts
Assembling instruction ProE code 64772023 E
Optional selection +H354+H356+H362: DC/brake busbars
64769359
Insulating supports and connecting busbars
Front
H356
Pedestal DC busbar kit R8
Pedestal DC busbars
Pedestal when
DC busbars
installed
Front
64744755
Terminals
H362
DC output busbar kit R8
Insulating supports
Side busbars
Front
Mechanical installation of non-pre-assembled units (ACS800-04M)
67
ACS800-04M of frame size R8 with busbars on the long side
Package
Parts
Assembling instruction ProE code 64772023 E
Optional selection +H354+H356+H363: DC and brake busbars on opposite sides
64744798
DC output on the right side:
Support brackets
Terminal
Output busbar
Insulating support
Long DC busbar for the pedestal
Front
Bilateral DC output busbar kit R8
+H363
DC output on the right
Brake output on the
right and DC output on
the left
Mechanical installation of non-pre-assembled units (ACS800-04M)
68
Control panel holder
+J413
ACS800-04M of frame size R8 with busbars on the long side
Package
Parts
Assembling instruction ProE code 64772023 E
Optional selection +J413: Control Panel Holder RPMP-21
68394961
Control panel holder
Mechanical installation of non-pre-assembled units (ACS800-04M)
69
ACS800-04M of frame size R8 with busbars on the long side
Package
Parts
Assembling instruction ProE code 64772023 E
Example assembly (+H354+H355+H356+H362+H363 included): AC and brake or DC busbars on the left, brake or
DC busbars on the right
View when vertical busbars are not
connected
View with vertical busbars connected
Note: All possible installation positions are shown. Actually DC
and brake busbars can only be located on one side each.
Front
+H355
+H362
+H363
+H356
+H354
Mechanical installation of non-pre-assembled units (ACS800-04M)
70
+B060
Top entry busbar shroud kit
ACS800-04M of frame size R8 with busbars on the long side
Package
Parts
Assembling instruction ProE code 64772023 E
Optional selection +B060: shrouds for vertical busbars and input terminals
68341493
Top entry busbar shroud
Fastening screws included
Mechanical installation of non-pre-assembled units (ACS800-04M)
71
ACS800-04M of frame size R8 with busbars on the long side
Parts
Assembling instruction ProE code 64772023 E
Package
68329639
+B060
Vertical busbar shroud kit
Vertical busbar shrouds
Alternative
positions
Fastening screws included
Mechanical installation of non-pre-assembled units (ACS800-04M)
72
ACS800-04M of frame size R8 with busbars on the long side
Package
Parts
Assembling instruction ProE code 64772023 E
Example assembly (+H354+H355+H356+H362+B060+Q950 included): top entry busbar shroud, vertical busbar
shroud and Prevention of Unexpected Start
+B060
600 mm (23.62 in.)
Front
+B060
1
=
GND
2
=
N
3
=
L
Terminal block for user
connection of Prevention of
Unexpected Start (+Q950 ).
The other end of the cable is
connected to AGPS board
terminal X1. The terminal
block can be fastened to the
cabinet frame or wall with
screws.
Note: The protective
films on the shrouds
must be removed
before installing.
+Q950 Prevention of
Unexpected Start.
Location of AGPS
board.
Mechanical installation of non-pre-assembled units (ACS800-04M)
73
Assembling procedure for units with busbars on the long side (+H354)
Working order
References to instructions in this chapter are printed in italic in the table below. The
pictures represent frame size R7 with the following orientations.
Front
Pedestal viewed from above
Left
Right
Step
1
Preparing
the pedestal
W2
V2
U2
W2
V2
U2
W2
V2
U2
RUDC+/R+
UDC-
W2
V2
U2
R-
UDC+/R+
UDC-
W2
V2
U2
R-
UDC+/R+
UDC-
If
AC busbars on
the left side
Instruction
Go to step 2.
AC busbars on
the right side
1. See Swapping the busbars of the pedestal to the other side on
page 78.
2. Go to step 2.
AC busbars, R-, 1. See Connecting the DC busbars to the pedestal (+H356 and
R+/UDC+ and
+H363 only) on page 76.
UDC- busbars on 2. Go to step 2.
the left side
(+H356 required)
AC busbars, R-, 1. See Swapping the busbars of the pedestal to the other side on
R+/UDC+ and
page 78.
UDC- busbars on 2. See Connecting the DC busbars to the pedestal (+H356 and
the right side
+H363 only) on page 76.
(+H356 required) 3. Go to step 2.
AC busbars and
R-, R+/UDC+
busbars on the
left side and
UDC+ and UDCbusbars on the
right side
1. See Swapping the busbars of the pedestal to the other side on
page 78 and Optional selection +H363 on page 79.
2. See Connecting the DC busbars to the pedestal (+H356 and
+H363 only) on page 76.
3. Go to step 2.
(+H356 and
+H363 required)
Mechanical installation of non-pre-assembled units (ACS800-04M)
74
Step
W2
V2
U2
R-
UDC+/R+
UDC-
(+H356 and
+H363 required)
Base mounting
from outside
2
Fastening
the pedestal
by the base
W2
V2
U2
(not performed
for wallmounted units)
W2
V2
U2
3
If
AC busbars and
UDC+ and UDCbusbars on the
left side and R-,
R+/UDC+
busbars on the
right side
2. See Connecting the DC busbars to the pedestal (+H356 and
+H363 only) on page 76.
3. Go to step 2.
1. See Clamping the pedestal with the outside brackets on page
80.
2. Go to step 3.
Base mounting
from inside
1. See Fastening the pedestal through the holes inside the
pedestal on page 80.
2. Go to step 3.
Units with vertical 1. See Fastening the output busbars and PE terminal and sliding
busbars
the module in on page 86.
2. See Fastening the drive module to the pedestal on page 89.
Fastening
the busbars
and module
to the
pedestal
3. Go to step 4.
Units with no
vertical busbars
4
Instruction
1. See Swapping the busbars of the pedestal to the other side on
page 78 and Optional selection +H363 on page 79.
1. See Fastening the drive module to the pedestal on page 89.
2. Go to step 4 (wall-mounted units) or 5 (base-mounted units).
wall-mounted unit See Fastening the drive module to wall (wall-mounted units only,
not for base-mounted units) on page 81.
Wall
mounting
Mechanical installation of non-pre-assembled units (ACS800-04M)
75
Step
5
If
base-mounted
unit
Instruction
See Fastening the drive module by top to the cabinet frame on
page 81.
if included
Frame size R7
Fastening by
top
6
Fastening
shrouds
See Top entry busbar shroud in section Fastening the top entry
busbar and bottom exit shrouds (+B060) on page 55.
Frame size R8
See Fastening the shrouds in frame size R8 on page 90.
Mechanical installation of non-pre-assembled units (ACS800-04M)
76
Connecting the DC busbars to the pedestal (+H356 and +H363 only)
Procedure
1. Screw insulating supports (“a” below) onto the free pins (“b” below) on the inner
sides of the pedestal.
2. Push busbars (c) through the R-, R+/UDC+ and UDC- lead-through insulators as
the W2, V2 and U2 busbars.
3. Connect the connecting busbars (d, e, f) to the insulating supports and to the R-,
R+/UDC+ and UDC busbars as shown below.
For +H363, see also Optional selection +H363 on page 79.
Photos of frame size R7
d
a
b
e
a
c
R-
f
R+ UDC-
a
UDC+
d
e
DC busbars connected
PE busbar
f
Mechanical installation of non-pre-assembled units (ACS800-04M)
77
Photos of frame size R8
d
a
b
c
a
R-
e
R+ UDCUDC+
d
a
f
e
DC busbars connected
f
Mechanical installation of non-pre-assembled units (ACS800-04M)
78
Busbars to the left- or right-hand side of the module?
The pedestal is delivered from the factory ready for left-hand side busbar
connections. When required, the internal busbars of the pedestal can be swapped to
the right side.
Swapping the busbars of the pedestal to the other side
When swapping the busbars from left to right, proceed as follows:
1. Turn the pedestal over to access the bolts which connect the pedestal power
connections to the horizontal busbars.
2. Undo the connections.
3. Pull out the busbars and rotate them 180 degrees.
4. Reinsert the busbars so that the busbar ends with the hole protrude on the righthand side of the pedestal.
5. Positions the busbars so that the small hole in the busbar is aligned with the hole
in the insulator.
6. Tighten the connections (2).
7. Connect the right-hand side PE terminal.
3
3
5
2
4
3
2
4
3
4
Busbar after turning around
4
2
3
2
3
2
4
New position
of the busbar
3
2
4
Pedestal upside down (busbar ends at
the left, PE terminal at the right)
7
Plain washer with electroplated zinc
coating and passivation
2 M10x30 (frame size R7)
M12x35 (frame size R8)
Spring washer with mechanically
sprayed zinc coating
Mechanical installation of non-pre-assembled units (ACS800-04M)
79
Optional selection +H363
This selection enables the connection of the DC output and the brake resistor output
to the opposite sides of the pedestal. The installation below requires also optional
selection +H356. The UDC- busbar and R- busbar are taken from the +H356 parts,
the R+/UDC+ busbar from the +H363 parts. For instruction on how to connect the
busbars to the pedestal frame, see Connecting the DC busbars to the pedestal
(+H356 and +H363 only) on page 76.
1. Connect the UDC- busbar.
2. Connect the R+/UDC+ busbar.
3. Connect the R- busbar.
1
UDC-
R+
2
UDC+
R-
3
U2
V2
W2
Pedestal upside down
DC output connected to the right
Mechanical installation of non-pre-assembled units (ACS800-04M)
80
Fastening the pedestal to the cabinet base (not for wall-mounted units)
Fasten the pedestal to the base of the cabinet either with the outside fastening
brackets or by using the fastening holes inside the pedestal.
Note: Place the module on a solid base. The fastening brackets are not strong
enough to carry the weight of the module on their own.
Clamping the pedestal with the outside brackets
1. Fasten the front bracket to the pedestal with two screws.
2. Fasten the back fastening bracket onto the cabinet floor with two screws.
3. Place the pedestal on the cabinet floor and push it so that the tabs of the
fastening bracket enter the slots in the pedestal.
4. Fasten the front bracket to the base with two screws.
2
2
3
1
M8
M8 (5/16 in.)
4
4
Tightening torque: 5 Nm (3.7 lbf ft)
Fastening the pedestal through the holes inside the pedestal
Fasten the pedestal to the base of the cabinet with four screws through the inside
fastening points.
M6, 5 Nm (3.7 lbf ft)
Mechanical installation of non-pre-assembled units (ACS800-04M)
81
Fastening the drive module by top to the cabinet frame
In addition to the base fastening, it is recommended to fasten the module to the
cabinet also from the fastening points at the top. Refer to Dimensional drawings for
the vertical fastening points.
If the module is not fastened from the back top to the cabinet frame, it must be
fastened from the front top fastening points during transportation or in case of
vibration.
Fastening the drive module to wall (wall-mounted units only, not for base-mounted
units)
Requirements for protection
The drive module must be protected against contact, dust and humidity (see chapter
Technical data in ACS800-04/04M/U4 Hardware Manual [64671006 (English)].
Requirements for the wall
The wall must be as close to vertical as possible, of non-flammable material and
strong enough to carry the weight of the unit. Check that there is nothing on the wall
to inhibit the installation.
Floor
The floor/material below the installation must be non-flammable.
Mechanical installation of non-pre-assembled units (ACS800-04M)
82
Procedure
• Place the wall mounting bracket onto the pedestal so that its pins enter the slots
of the pedestal.
• Fasten the pins with nuts (1) from inside or fasten the bracket with screws from
outside (2). The nuts and screws are included in the mounting bracket package.
Inserting the wall
mounting bracket into the
slots in the pedestal
1
2
2
1
The pins of the wall mounting bracket are fastened with
nuts from inside
Fastening the wall mounting bracket with screws from
outside (alternative to pin fastening from inside)
Mechanical installation of non-pre-assembled units (ACS800-04M)
83
• See Dimensional drawings for locations of the fastening points at the top of the
module.
• Use a pallet truck or a lifter to move the unit to the final mounting place.
WARNING! Secure the unit to eliminate the danger of overturning and falling
during the fastening precedure.
• Fasten the module through the slots in the wall mounting bracket and the
fastening holes at the top of the module using spacers between the module and
the wall.
Note: In flat mounting, the spacers (at the top and bottom) provide a clearance of 15 mm (0.6 in.)
between the drive module and the wall so that the protruding studs of the module will not press
against the wall. In bookshelf mounting, the spacer removes a 4 mm (0.16 in.) gap between the
drive module top and the wall so that the module will hang in an upright position.
• Fasten the module also by top front with a wall-fastened support bracket.
Mechanical installation of non-pre-assembled units (ACS800-04M)
84
Units with busbars on the short sides (flat mounting, frame sizes R7 and R8)
15 mm (0.6 in.)
View from above
Spacer viewed from front (frame size R7)
Side view
R7
View from below
Screw size: M10 for frame sizes R7 and R8
Fastening points of frame size R8
Top
Bottom
Mechanical installation of non-pre-assembled units (ACS800-04M)
85
Units with busbars on the long side (bookshelf mounting, frame sizes R7 and R8)
4 mm (0.6 in.)
Frame size R7 with spacer
Frame size R8: no spacer
View from above
no spacer
Spacer (frame size R7)
Side view
Screw size: M10 for frame sizes R7 and R8
Fastening points of frame size R7
Top
Bottom
Mechanical installation of non-pre-assembled units (ACS800-04M)
86
Fastening the output busbars and PE terminal and sliding the module in
The steps of this installation procedure are shown in the photos on the next pages.
1. Connect the output busbars to the pedestal.
2. Fasten the PE terminal.
3. Screw the insulating supports onto the pins on the outer support bracket.
4. Fasten the output busbars and terminals to the insulating supports on the outer
support bracket.
5. Fasten the inner support bracket to the drive module.
M6x16
R7
M6x12
R8
6. Remove the fastening brackets (screws “b” on photos under Fastening the drive
module to the pedestal on page 89) from the pedestal.
7. Slide the module onto the pedestal so that the inner support bracket enters inside
the outer support bracket.
8. Fasten the outer support bracket to the drive module.
9. Fasten the stickers to the output busbars.
Mechanical installation of non-pre-assembled units (ACS800-04M)
87
View of output busbar connections of frame size R7 (DC and brake busbars included)
Top view of insulating support and cable
lug terminal connections
Insulating support
M8x16
M8x20
M10x25
Cable lug
terminal
3
WARNING! Fasten the output busbars to the insulating supports with M8x16 screws when
no cable lug terminal is connected, but with M8x20 screws when a cable lug terminal is also
connected with the same screw. Screwing an M8x20 screw without a cable lug terminal
through the busbar into the insulating support will break the insulating support. Fasten the
cable lug terminals elsewhere with M10x25 screws.
4
4
8
4
Tightening torque
M8: 15...22 Nm (3.7 lbf ft)
M10: 30...44 Nm (22...32 lbf ft)
9
R-
Nut
1
Spring washer with
mechanically sprayed zinc
coating
Plain washer with
electroplated zinc coating
and passivation
M10x30
M8
2
1
Mechanical installation of non-pre-assembled units (ACS800-04M)
88
View of output busbar connections of frame size R8 (DC and brake busbars included)
WARNING! Fasten the output busbars to the insulating supports with M10x20
screws when no cable lug terminal is connected, but with M10x25 screws when a
cable lug terminal is connected as well. Screwing an M10x25 screw without a
cable lug terminal through the busbar into the insulating support will break the
insulating support.
M10x25
M10x20
M10x25
4
4
4
4
4
4
4
4
4
3
8
5
4
4
W2
9
V2
U2
4
R-
R+
UDC+
UDC-
M10
2 pcs
Nut
2
1
Tightening torque
M10: 30...44 Nm (22...32 lbf ft)
M12: 50...75 Nm (37...55 lbf ft)
Mechanical installation of non-pre-assembled units (ACS800-04M)
M12x35
Spring washer with
mechanically sprayed zinc
coating
Plain washer with
electroplated zinc coating
and passivation
89
Fastening the drive module to the pedestal
• Remove the front cover of the module.
• Connect the busbars with screws [3 to 6 pcs (a)] using a torque wrench with an
extension bar.
• Fasten the module to the pedestal with screws (b).
WARNING! Fastening of screws (b) is important because the screws are required
for the grounding of the drive.
Frame size R7
a
a M8x25 combi screw
Tightening torque: 15...22 Nm
(11...16 lbf ft)
b
a
a
b
b
a
a
b
b M6 combi screw
Tightening torque: 5 Nm (3.7 lbf ft)
a
Pedestal
U2
UDC-
V2
UDC+
W2
Frame size R8
b
a a
a
a
b
b
b
a
a M10x25 combi screws
Tightening torque: 30...44 Nm (22...32 lbf ft)
b M6x16 combi screws
Tightening torque: 5 Nm (3.7 lbf ft)
• Match the three guide pins on the cover with the counter holes. Fasten the front
cover to the module with screws.
Mechanical installation of non-pre-assembled units (ACS800-04M)
90
Fastening the shrouds in frame size R8
Top entry busbar shroud
4
3
4
Place the top cover to
position (3) with the tabs
entering the slots of the
shroud.
Fasten the
shroud to the
drive module.
2 Remove the protective
film.
1
Step drill lead-throughs
for the busbars.
Top entry busbar shroud fastened
Vertical busbar shroud
2
Remove the protective film from the
shroud surfaces.
Alternative
positions
Used in the righthand-side assembly
1
Cut the corner piece
to make space for
the PE terminal of
the drive module.
3
Fasten the shroud plates to
each other and to the drive
module.
Vertical busbar shroud fastened
Note: When connecting the power cables,
remove the front (and top and side) shroud by
undoing the fastening screws.
Mechanical installation of non-pre-assembled units (ACS800-04M)
91
Units with pedestal and busbars on the short side (+H360, flat mounting)
Delivery check
Check that there are no signs of damage. Before attempting installation and
operation, check the information on the type designation label of the drive to verify
that the unit is of the correct type.
Item packages
The following tables show what each item package contains:
• parts
• part list code
• plus code
• assembling instruction.
In the tables, the basic unit is described first, then the possible optional parts are
listed. Choose the table and options of your delivery in the following sections:
• Item packages of frame size R7 with busbars on the short side on page 92.
• Item packages of frame size R8 with busbars on the short side on page 98.
Note: The complete assembling instructions are represented under Assembling
procedure for units with busbars on the short side (+H360) on page 104.
Mechanical installation of non-pre-assembled units (ACS800-04M)
92
Item packages of frame size R7 with busbars on the short side
Package
ACS800-04M with busbars on the short side (frame size R7)
Parts
Assembling drawing / reference to instruction
ProE code 64770306 D
Basic unit (type code ACS800-04M-xxxx-x+H355+H360)
Refer to section Assembling procedure for units with
busbars on the short side (+H360) on page 104.
Drive module
See RDCU Drive Control Unit Hardware Manual
[3AFE64636324 (English)].
RDCU drive control unit
(RDCU)
Drive control unit
-
Front
Mechanical installation of non-pre-assembled units (ACS800-04M)
93
ACS800-04M with busbars on the short side (frame size R7)
Parts
Assembling drawing / reference to instruction
Package
ProE code 64770306 D
64749404
Pedestal
Pedestal R7 +H360
Base mounting if clamped
from outside
Front
Spacers for wall
mounitng
grounding terminal kit R7 +H360
Mounting bracket and
64745808
PE terminals
Base mounting
brackets
Wall mounting
Wall mounting bracket
Note: DC and brake busbars (+H356) are
included in the drawing
64749391
+H360
Adapter R7
Front (view from above)
Adapter (viewed
from the side that
will mate with the
drive module)
Mechanical installation of non-pre-assembled units (ACS800-04M)
94
ACS800-04M with busbars on the short side (frame size R7)
Parts
Assembling drawing / reference to instruction
Package
ProE code 64770306 D
64744402
Motor output busbar kit R7 + H355
Insulating
supports
AC support
brackets
Motor cable
terminals
AC output busbars
Front
Control panel holder
+J413
Optional selection +J413: Control Panel Holder RPMP-21
68394961
Control panel holder
Mechanical installation of non-pre-assembled units (ACS800-04M)
95
Package
ACS800-04M with busbars on the short side (frame size R7)
Parts
Assembling drawing / reference to instruction
ProE code 64770306 D
Optional selection +H360+H356+H362: DC/brake busbars
64769375
+H356 (+H360 required)
Adapter DC busbar kit R7
Insulating supports
Front (view from above)
Connecting busbars
Insulating supports
+H356 (+H360 required)
Pedestal DC busbar kit R7
Front
Connecting busbars
Pedestal DC busbars
Mechanical installation of non-pre-assembled units (ACS800-04M)
96
ACS800-04M with busbars on the short side (frame size R7)
Parts
Assembling drawing / reference to instruction
Package
ProE code 64770306 D
64744763
DC output busbar kit R7
+H362 (+H360 required)
Insulating
supports
DC support
brackets
Terminals
Side busbars
Front
Mechanical installation of non-pre-assembled units (ACS800-04M)
97
Package
ACS800-04M with busbars on the short side (frame size R7)
Parts
Assembling drawing / reference to instruction
ProE code 64770306 D
Example assembly +H360+H355+H356+H362: DC and brake busbars included
500 mm (19.68 in.)
1
=
GND
2
=
N
3
=
L
Terminal block for user connection
of Prevention of Unexpected Start
(+Q950 ). The other end of the
cable is connected to AGPS board
terminal X1. The terminal block
can be fastened to the cabinet
frame or wall with screws.
+Q950 Prevention of
Unexpected Start.
Location of AGPS
board.
+H355
Front
+H362
+H360
+H356
Mechanical installation of non-pre-assembled units (ACS800-04M)
98
Item packages of frame size R8 with busbars on the short side
Package
ACS800-04M with busbars on the short side (frame size R8)
Parts
Assembling drawing / reference to instruction
ProE code 64772023 E
Basic unit (type code ACS800-04M-xxxx-x+H355+H360)
Refer to section Assembling procedure for units with
busbars on the short side (+H360) on page 104.
Drive module
See RDCU Drive Control Unit Hardware Manual
[3AFE64636324 (English)].
RDCU drive control unit
(RDCU)
Drive control unit
-
Front
Mechanical installation of non-pre-assembled units (ACS800-04M)
99
ACS800-04M with busbars on the short side (frame size R8)
Parts
Assembling drawing / reference to instruction
Package
ProE code 64772023 E
64749978
Pedestal R8 +H360
Pedestal
Spacers for wall
mounting
Front
Front
Upper
Wall mounting
Lower
64745794
Insulating support
PE terminal
L-bracket (used when U2 output
busbar is not installed)
grounding terminal kit R8 +H360
Mounting bracket and
Base mounting
brackets
Wall mounting
bracket
Front
Base mounting if clamped from outside
Front
PE busbar if pedestal busbars are
swapped to the left. Note: vertical busbars
cannot be used.
Mechanical installation of non-pre-assembled units (ACS800-04M)
100
ACS800-04M with busbars on the short side (frame size R8)
Parts
Assembling drawing / reference to instruction
Package
ProE code 64772023 E
Adapter (viewed
from the side that
will mate with the
drive module)
+H360
Adapter R8
64749871
View from above
Front
64744453
Motor output busbar kit R8 + H355
Insulating supports
Motor cable terminals
AC support brackets
AC output busbars
Front
Control panel holder
+J413
Optional selection +J413: Control Panel Holder RPMP-21
68394961
Control panel holder
Mechanical installation of non-pre-assembled units (ACS800-04M)
101
Package
ACS800-04M with busbars on the short side (frame size R8)
Parts
Assembling drawing / reference to instruction
ProE code 64772023 E
Optional selection +H356+H362+H360: DC/brake busbars
64769456
Insulating
supports
View from above
+H356 (+H360 required)
Adapter DC busbar kit R8
Front
Connecting busbars
Front
Adapter when
DC busbars
installed
Mechanical installation of non-pre-assembled units (ACS800-04M)
102
ACS800-04M with busbars on the short side (frame size R8)
Parts
Assembling drawing / reference to instruction
Package
ProE code 64772023 E
Insulating supports
Front
+H356 (+H360 required)
Pedestal DC busbar kit R8
Connecting busbars
Front
Pedestal DC busbars
Pedestal
when DC
busbars
installed
64744771
M10x20
Insulating
supports
DC output busbar kit R8
M10x25
+H362 (+H360 required)
Terminals
Side busbars
M10x35
Mechanical installation of non-pre-assembled units (ACS800-04M)
Front
103
Package
ACS800-04M with busbars on the short side (frame size R8)
Parts
Assembling drawing / reference to instruction
ProE code 64772023 E
Example assembly +H355+H356+H360+H362: DC/brake busbars included
View when vertical busbars are not
connected
+H360
Front
View with vertical busbars
connected
+H362
+H356
+H355
+H360
Mechanical installation of non-pre-assembled units (ACS800-04M)
104
Assembling procedure for units with busbars on the short side (+H360)
Working order
References to instructions in this chapter are printed in italic in the table below. The
pictures represent frame size R7 with the following orientations.
Front
Pedestal viewed from above
Left
Step
Right
If
1
AC busbars on
W2 the right side
V2
U2
Preparing
the pedestal
Instruction
Go to step 2.
AC busbars, R-, 1. See Connecting the DC busbars to the pedestal
R+/UDC+ and
(+H360 +H356 only) on page 107.
UDC- busbars on 2. Go to step 2.
the right side
(+H356 required)
W2
V2
U2
AC busbars on
the left side
1. See Swapping the pedestal output busbars to the
left-hand side on page 106.
2. Go to step 2.
AC busbars, R-, 1. See Swapping the pedestal output busbars to the
R+/UDC+ and
left-hand side on page 106.
UDC- busbars on 2. See Connecting the DC busbars to the pedestal
the left side
(+H360 +H356 only) on page 107.
(+H356 required) 3. Go to step 2.
2
Preparing
the adapter
AC busbars on
the right or left
side
Go to step 3.
AC busbars, R-, 1. See Preparing the adapter (+H360 +H356 only) on
R+/UDC+ and
page 108.
UDC- busbars on 2. Go to step 3.
the right or left
side
(+H356 required)
Mechanical installation of non-pre-assembled units (ACS800-04M)
105
Step
3
If
Instruction
1. See Fastening the adapter to the drive module on
page 109.
-
2. Go to step 4.
Fastening
the adapter
to the drive
module
4
Base mounting
from outside
2. Go to step 5.
Fastening
the pedestal
by the base
(not performed
for wallmounted units)
Base mounting
from inside
5
-
1. See Fastening the drive module to the pedestal via
the adapter on page 110.
2. Go to step 6.
Units with vertical 1. See Connecting the output busbars on the short side
busbars
of the module on page 111.
2. Go to step 7.
Connecting
the output
busbars
7
Wall
mounting (not
1. See Fastening the pedestal through the holes inside
the pedestal on page 80.
2. Go to step 5.
Fastening
the adapter
to the
pedestal
6
1. See Clamping the pedestal with the outside brackets
on page 80.
wall-mounted unit 1. See Fastening the drive module to wall (wallmounted units only, not for base-mounted units) on
page 81.
performed for
base-mounted
units)
8
base-mounted
unit
1. See Fastening the drive module by top to the cabinet
frame on page 81.
Fastening by
top
Mechanical installation of non-pre-assembled units (ACS800-04M)
106
Swapping the pedestal output busbars to the left-hand side
• Disconnect the horizontal pedestal busbars from the busbars that connect them
to the adapter.
• Push the horizontal busbars to the left.
• Reconnect the horizontal busbars to the adapter connecting busbars.
Note:
When the pedestal busbars are swapped to the left:
• vertical output busbars cannot be installed.
• the unit cannot be mounted on a wall with the wall mounting bracket included in
the delivery.
• ensure that the required clearance between the cabinet base or floor and the
cable lugs or busbars used in the cabling is at least 13 mm (1/2 in.). Otherwise,
insulating material must be used below the drive module.
• fasten the left-hand side PE terminal in frame size R7. In frame size R8, fasten
the PE busbar as follows.
Left
Right
Front (the profiled side)
PE busbar
Fastening of the PE busbar in frame size R8
Mechanical installation of non-pre-assembled units (ACS800-04M)
107
Connecting the DC busbars to the pedestal (+H360 +H356 only)
Required parts
Frame size R7
a
a
a
d
e
f
b
R+
UDC+
c
UDC-
c
c
R-
Procedure
1. Screw insulating supports (“a” above) onto the free pins (“b” above) on the inner
sides of the pedestal.
2. Push busbars (c) through the R-, R+/UDC+ and UDC- lead-through insulators.
3. Connect the connecting busbars (d, e, f) to the insulating supports and to the R-,
R+/UDC+ and UDC busbars as shown below.
e
Frame size R7
f
DC busbars connected
d
Frame size R8
See also chapter Assembly drawings.
Mechanical installation of non-pre-assembled units (ACS800-04M)
108
Preparing the adapter (+H360 +H356 only)
Required parts
Frame size R7
a
b
a
Frame size R8
a
b
b
a
a
b
a
f
c
e
c
f
d
e
b
a
d
Procedure
1. Screw insulating supports (“a” above) onto the free pins (“b” above).
2. Connect the connecting busbars to the insulating supports as shown below.
Connect busbar c to busbar d.
Frame size R7
Frame size R8
f
f
c
e
e
c
d
d
See also chapter Assembly drawings.
Mechanical installation of non-pre-assembled units (ACS800-04M)
109
Fastening the adapter to the drive module
The DC busbars (+H356) are included in the installation examples below.
1. Fasten the screws.
2. Connect the busbars.
Frame size R7
Frame size R8
1
1
2
1
1
2
2
2
2
1
2
1
2
2
2
2
1
1
2
1
1
2
1
1
2
Tightening torque
M8: 15...22 Nm (3.7 lbf ft)
2
Tightening torque
M10: 30...44 Nm (22...32 lbf ft)
Mechanical installation of non-pre-assembled units (ACS800-04M)
110
Fastening the drive module to the pedestal via the adapter
The DC busbars (+H356) are included in the installation examples below. The
adapter has been connected to the drive module.
1. Frame size R7: Remove the “long front” side plate of the pedestal.
Frame size R8: Remove the “long front” side plate of the adapter.
2. Slide the drive module with the adapter fastened onto the pedestal.
3. Connect the busbars.
4. Frame size R7: Fasten the side plate of the pedestal.
Frame size R8: Fasten the side plate to the adapter and the pedestal.
Frame size R7
3
2
1
1
M6
M6
M5
4
M5
M5
Frame size R8
1
1
4
2
4
3
Mechanical installation of non-pre-assembled units (ACS800-04M)
4
111
Connecting the output busbars on the short side of the module
Procedure for frame size R7
The steps of this installation procedure are shown in the photos below and on the
next page.
1. Fasten the inner support bracket (brackets if DC busbars ordered) to the drive
module with four M6 screws.
2. Screw the insulating supports onto the pins on the outer support bracket (s).
3. Slide the outer support bracket(s) on the inner bracket(s).
4. Fasten the outer support bracket(s) with two M6 screws.
5. Connect the AC busbars.
6. Connect the DC busbars (if ordered).
7. Connect the cable lug terminals. Use a M8x20 screw when the terminal is placed
on an insulating support and M10x25 screws elsewhere.
8. Connect the PE busbar.
1
3
1
2
4
5
M8x16
without
cable lug
terminal,
M8x20 with
cable lug
terminal
M10
5
Mechanical installation of non-pre-assembled units (ACS800-04M)
112
M10x25
M10x25
7
M8x16
M8x20
WARNING! Fasten the output
busbars to the insulating supports
with M8x16 screws when no cable
lug terminal is connected, but with
M8x20 screws when a cable lug
terminal is connected as well.
Screwing an M8x20 screw without
a cable lug terminal through the
busbar into the insulating support
will break the insulating support.
5
M8x16
M10x25
Tightening torque
M8: 15...22 Nm (3.7 lbf ft)
M10: 30...44 Nm (22...32 lbf ft)
M10
5
8
M8. Use the side plate fastening screw
for fastening the PE terminal by side.
PE
6 M10
Frame size R7 +H360: AC, DC and brake busbars connected (+H356 included)
Mechanical installation of non-pre-assembled units (ACS800-04M)
113
Procedure frame size R8
The steps of this installation procedure are shown in the photo on the next page.
1. Fasten the inner support bracket to the drive module.
2. Screw the insulating supports onto the pins on the outer support bracket.
3. Slide the outer support bracket on the inner bracket.
4. Fasten the outer support bracket to the drive module.
5. Connect the AC busbars.
6. Connect the DC busbars (if ordered).
7. Connect the PE busbar.
Mechanical installation of non-pre-assembled units (ACS800-04M)
114
1
WARNING! Fasten the output busbars to the
insulating supports with M10x20 screws when no
cable lug terminal is connected, but with M10x25
screws when a cable lug terminal is connected as
well. Screwing an M10x25 screw without a cable lug
terminal through the busbar into the insulating
support will break the insulating support.
4
5
2
Tightening torque
M10: 30...44 Nm (22...32 lbf ft)
M12: 50...75 Nm (37...55 lbf ft)
7
PE
M10
M10
7
Nut
6
Spring washer with
mechanically sprayed zinc
coating
Plain washer with
electroplated zinc coating
and passivation
5
M12x35
Frame size R8 +H360: AC, DC and brake busbars connected (+H356 included)
Mechanical installation of non-pre-assembled units (ACS800-04M)
115
Checking the installation
What this chapter contains
This chapter contains checklists according to which the assembly of converter
modules into a cabinet is inspected at ABB factory.
Visual inspection
Inspect the mechanical and electrical installation of the converter module visually to
ensure safe testing and use of the drive.
Cabinet construction
Checks for cabinet construction are listed below.
Step
1
1.1
1.2
1.3
Check item
Cabinet construction
Frame, wall, floor and roof structures, busbar enclosures and cable entries are correct and completely
assembled.
Mechanical joints are tightened and not broken.
Parts are clean and painted surfaces not scratched.
1.4
1.5
The cabinet frame and parts which are in metal to metal contact with the frame (e.g. seams,
component fixing points on assembly plates, back of control panel mounting plate) are not finished
with non-conducting paint or material.
IP enclosure class
There is a sufficient number of supports, bolts and nuts for cables.
Instrumentation, busbars and cabling
Checks for instrumentation, busbars, cabling, clearances and creepage distances
are listed below. For more information, refer to ACS800-04/04M/U4 Hardware
Manual [3AFE64671006 (English)]: Planning the electrical installation.
Step
2
2.1
2.2
2.3
2.4
Check item
Instrumentation
Type and number of option modules and other equipment is correct. Option modules and other
equipment are not damaged.
Option modules and terminals are labelled correctly.
The placement of option modules and other equipment inside the cabinet and on the cabinet door is
correct.
The mounting of option modules and other equipment is correct.
Checking the installation
116
Step
3
3.1
3.2
3.3
3.4
3.5
3.6
4
4.1
Check item
Busbars
The types (Al/Cu) and cross-sections of busbars are correct.
Busbars are intact and joint surfaces are clean. There are no metal scraps on the busbars that could
cause a short-circuit.
The placement and mounting of busbars is correct.
The electrical connection of busbars. Check that the surfaces in electrical connections of aluminium
and uncoated busbars are rubbed. Check that anti-oxidant joint compound is used in electrical
connections of aluminium busbars. Check that the number of washers and the sizes of bolts are
correct.
Busbar supports and lead-in insulators are visually intact and degreased, and placed and mounted
correctly.
The electrical connections on the main circuit are tightened to required torque and marked with a
green marking.
Cabling and wiring
Wiring of the main circuit. Check
• AC supply input
• AC output
4.2
• supply for brake resistor (if used).
Wiring of the 230 VAC circuit. Check
• terminal strips and relays
• supply of cabinet fans (if used)
• 24 VDC auxiliary voltage circuit (optional module supply)
4.3
• supply for cooling fan of the braking resistor(s) (if used).
Wiring of the converter module circuit. Check
• RDCU module (RMIO board) connections
• control cable connections
4.4
4.5
4.6
• control panel cable connections.
Cable types, cross-sections, colours and optional markings are correct.
Check the cabling for circuits susceptible to interference. Check the twisting of cables and cable
routes.
Check that cables without short-circuit protection
• can carry the load current
• are shorter than 3 m (10 ft)
• are assembled separate to other cables
4.7
• are protected by an enclosure or duct.
Cable connectors and fibre optic cables are intact and according to instructions. Check the termination
of cables (e.g. AMP connectors), the crimping of cable lugs and ferrules. Check that the connectors
are suitable for the cables and the correct crimping tool has been used.
Check that
• insulation of the cable is not underneath the connector
• all strands of the cable are inside the connector
• connector is not broken
• cable is deep enough in its connector.
Checking the installation
117
Step
4.8
Check item
Connection of cables to devices and terminal blocks. Check that
• cables are connected to terminals tight enough by pulling the cable
• cable termination on terminals chaining is done correctly
4.9
4.10
5.
5.1
5.2
• bare conductors are not too far outside the terminal causing an insufficient clearance or loss of
shielding against contact.
Cables are not lying against sharp edges or bare live parts. Bending radius of fibre optic cables at least
3.5 cm (1.38 in.).
The type, markings, insulation plates and cross connections of terminal blocks are correct.
Clearances and creepage distances
Clearances outside the modules are at least 12.7 mm (0.5 in.).
Creepage distances outside the modules are at least 12.7 mm (0.5 in.).
Groundings and protection
Checks for groundings and protections are listed below. Tips for installations where
EMC emissions must be minimised are given in column Extra requirements for EMC.
Step
6
6.1
6.2
Check item
Extra requirements for EMC
Groundings and protection
The grounding colours, cross-section and grounding points No long routes for pigtails
of modules and other equipment match the circuit diagrams.
Connections of PE cables and busbars are tight enough.
No long routes for pigtails
Pull the cable to test that it does not loosen.
6.3
Doors equipped with electrical equipment are grounded.
6.4
6.5
Fans that can be touched are shrouded.
Live parts inside the doors are protected against direct
contact to at least IP 2x (if required).
No long grounding routes. From EMC standpoint
best result is achieved with a flat copper braid.
Checking the installation
118
Labels, switches, fuses and doors
Checks for labels, switches, fuses and doors are listed below.
Step
7
7.1
Check item
Labels
The name plates are correct. The name plates are located correctly. Check the name plates for
• cabinet
• main circuit fuses
• settings of the circuit-breakers
7.2
• safety switches of the main circuit.
The warning and instruction stickers are located correctly.
Stickers required inside the cabinet:
•
near all grounding connections
• inside the cabinet door main fuse specification label, fuse installation (centring) note
•
on contact covers
• warning of live terminals of a blown fuse on contact cover on the main fuses
• warning about apparatus not disconnected from the supply network by the main switch on contact covers of
these busbars and apparatus
• warning sticker for residual voltages of the converter capacitor banks placed on the converter module.
Stickers required on the cabinet door:
• five-minute warning of residual voltage
•
• sticker on the control panel mounting platform (if used)
• emergency stop and start switch label (if applicable)
8.
8.1
8.2
8.3
• main switch label.
Switches, fuses and doors
Check the functioning of mechanical switches by closing and opening them.
Check that fuses can be changed with a fuse handle. Check that fuse disconnectors and sockets match each
other.
Check the appropriate length and fastening of the operation rod of the main disconnecting switch.
When switch fuses or disconnecting switches are closed, the corresponding cabinet doors cannot be opened:
1. Lock the cabinet door with the main switch in OPEN position (0).
2. Close the main switch (position 1).
3. Unlock the door. It must not be possible to open the door by pulling the handle.
Checking the installation
119
Dimensional drawings
Dimensional drawings
120
Frame size R7 without pedestal (mm)
Center of
gravity
64796003_3/7 E
Dimensional drawings
121
64796003_6/7 G
Frame size R7 with bottom exit (mm)
Dimensional drawings
122
64796003_7/7 E
Frame size R7 with bottom exit and top entry and bottom exit shrouds
(mm)
Dimensional drawings
123
64796003_5/7 G
Frame size R7 with busbars on the left side (mm)
Dimensional drawings
124
64796003_2/7 G
Fastening bracket
for wall mounting only
Bilateral busbar
Frame size R7 with DC busbars on both sides (mm)
Dimensional drawings
125
Frame size R7 pedestal busbars on the long side (mm)
Bilateral output busbar
64796003_4/7 E
Dimensional drawings
126
64796003_1/7 G
Fastening bracket
for wall mounting only
Frame size R7 with busbars on the short side (mm)
Dimensional drawings
127
Frame size R8 without pedestal (mm)
Center of
gravity
64801082_3/6 E
Dimensional drawings
128
64801082_5/6 E
Frame size R8 with busbars on the left side (mm)
Dimensional drawings
129
Frame size R8 with top entry and vertical busbar shrouds (mm)
64801082_6/6 E
Dimensional drawings
64801082_1/6 E
Fastening bracket
for wall mounting only
Bilateral busbar
130
Frame size R8 with busbars on both sides (mm)
Dimensional drawings
131
Frame size R8 pedestal busbars on the long side (mm)
Bilateral output busbar
64801082_4/6 E
Dimensional drawings
Dimensional drawings
64801082_2/6 E
Spacer for wall
mounting only
Base fastening
bracket
Spacer for wall
mounting only
Spacer for wall
mounting only
Fastening bracket for
wall mounting only
132
Frame size R8 with busbars on the short side (mm)
133
Wall mounting spacers
Frame size R7: long side against wall
68240808 B
Frame size R7: short side against wall
A
A
A-A
68240166 A
Frame size R8: long side against wall
68238021 A
Dimensional drawings
134
Frame size R8: short side against wall
68377927 A
Frame size R7 bottom exit kit (+H352)
64770306_16/20 E
Dimensional drawings
135
Frame size R7 top entry busbar shroud and bottom exit shroud (+B060)
64770306_18/20 E
64770306_17/20 E
Dimensional drawings
136
Control Panel Holder RPMP-21 (+J413)
64770306_20/20 E
Dimensional drawings
137
Drive Control Unit (RDCU-02)
Can be mounted on a DIN rail
(EN 50022, 35 mm x 7.5 mm)
64675214-B
Dimensional drawings
138
Dimensional drawings (USA)
Dimensional drawings
139
Frame size R7 without pedestal (inches)
Center of
gravity
68439221_3/7 A (64796003.asm E)
Dimensional drawings
140
68439221_6/7 F
F
F
Frame size R7 with bottom exit (inches)
Dimensional drawings
141
68439221_7/7 A (64796003.asm E)
Frame size R7 with bottom exit and top entry and bottom exit shrouds (inches)
Dimensional drawings
142
68439221_5/7 F
Frame size R7 with busbars on the left side (inches)
Dimensional drawings
143
68439221_2/7 F
Fastening bracket for
wall mounting only
Bilateral busbar
Frame size R7 with busbars on both sides (inches)
Dimensional drawings
144
Frame size R7 pedestal busbars on the long side (inches)
Bilateral output busbar
68439221_4/7 A (64796003.asm E)
Dimensional drawings
145
68439221_1/7 F
Fastening bracket
for wall mounting only
Frame size R7 with busbars on the short side (inches)
Dimensional drawings
146
Frame size R8 without pedestal (inches)
Center of
gravity
68440513_3/6 A (64801082.asm E)
Dimensional drawings
147
68440513_5/6 A (64801082.asm E)
Frame size R8 with busbars on the left side (inches)
Dimensional drawings
148
Frame size R8 with top entry and vertical busbar shrouds (inches)
68440513_6/6 A (64801082.asm E)
Dimensional drawings
68440513_1/6 A (64801082.asm E)
Fastening bracket
for wall mounting only
Bilateral busbar
149
Frame size R8 with busbars on both sides (inches)
Dimensional drawings
150
Frame size R8 pedestal busbars on the long side (inches)
Bilateral output busbar
68440513_4/6 A (64801082.asm E)
Dimensional drawings
68440513_2/6 A (64801082.asm E)
Spacer for wall
mounting only
Base mounting
bracket
Spacer for wall
mounting only
Spacer for wall
mounting only
Fastening bracket
for wall mounting only
151
Frame size R8 with busbars on the short side (inches)
Dimensional drawings
152
Dimensional drawings
153
Circuit diagrams
What this chapter contains
This chapter shows an example circuit diagram for employing the Prevention of
Unexpected Start function (+Q950).
Circuit diagrams
Circuit diagrams
00362825 B
Safety relay
Components to be provided and wired by the user
ACS800-04/04M drive module
154
155
Assembly drawings
What this chapter contains
This chapter shows a few step-by-step assembly drawings.
Assembly drawings
Assembly drawings
6844855 A
Combi screw
Combi screw
Combi screw
Basic assembly
UDC- busbars
Step 2
Combi screw
UDC+/R+ busbars
Step 3
R- busbars
Step 1
Combi screw
Combi screw
Combi screw
Combi screw
Combi screw
156
Adding UDC+/R+, UDC- and R- busbars to the pedestal (frame size R7,
+H356+H360)
68449359 A
Combi screw
UDC- busbar
Step 2
Basic assembly
Step 1
R- busbar
Step 3
Combi screw
UDC+/R+ busbar
Combi screw
157
Adding UDC+/R+, UDC- and R- busbars to the adapter (frame size R7,
+H356+H360)
Assembly drawings
Assembly drawings
68448905 A
Combi screw
UDC+/R+ busbar
UDC- busbar
Combi screw
Step 3
R- busbar
Step 2
Step 1
Basic assembly
Combi screw
Combi screw
Combi screw
Combi screw
158
Adding UDC+/R+, UDC- and R- busbars to the pedestal (frame size R8,
+H356+H360)
68448671 C
Combi screw
Combi screw
Basic assembly
Combi screw
R- busbar
Combi screw
Step 3
UDC+/R+ busbar
Combi screw
Combi screw
Step 2
Combi screw
UDC- busbar
Step 1
159
Adding UDC+/R+, UDC- and R- busbars to the adapter (frame size R8,
+H356+H360)
Assembly drawings
160
Assembly drawings
3AFE68360323 Rev B EN
EFFECTIVE: 14.2.2008
ABB Oy
AC Drives
P.O. Box 184
FI-00381 HELSINKI
FINLAND
Telephone
+358 10 22 11
Fax
+358 10 22 22681
Internet
www.abb.com
ABB Inc.
Automation Technologies
Drives & Motors
16250 West Glendale Drive
New Berlin, WI 53151
USA
Telephone
262 785-3200
800-HELP-365
Fax
262 780-5135
Internet
www.abb.com
ABB Beijing Drive Systems Co. Ltd.
No. 1, Block D, A-10 Jiuxianqiao Beilu
Chaoyang District
Beijing, P.R. China, 100015
Telephone
+86 10 5821 7788
Fax
+86 10 5821 7618
Internet
www.abb.com
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