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)

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.

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

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

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
.......................................................
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

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

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 units 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)

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

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 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

PE
3

PE
3

Air flow to the roof

IP 22

Air flow through the module

IP 54
Fan

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 Nm (2.6 lbfft)

M6

9 Nm (6.6 lbfft)

M8

20 Nm (14.8 lbfft)

M10

40 Nm (29.5 lbfft)

M12

70 Nm (52 lbfft)

M16

180 Nm (133 lbfft)

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
288292+688521
airTex G150
300
45
288292+688521
airTex G150

Min. cabinet air

outlet size*
mm
398312 (2 pcs)
398312 (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 manufacturers 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 288292 + 688521
398312 (2 pcs)
250*
RH35M-4EK.2F.1R by airComp 300-50
airTex G150
Ziehl-Abegg or RB4T- 288292 + 688521
398312 (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

Converter
module

Horizontal air baffle

Converter
module

Air flow in max. 40C (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

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

Tightening torques
M8: 15...22 Nm (3.7 lbf ft)

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

R-

UDC+

2
2

2
2

W2

V2

U2

R+

UDC-

M10
2 pcs

Nut

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

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)

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

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.

B
C

C
C

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

C
C

C
C

D
R+/UDC+

U2 V2

UDCW2

4. Fasten the front cover.

Mechanical installation of non-pre-assembled units (ACS800-04M)

RD

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).

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

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)