ACS800 Catalogue Related tools and accessories - …€¦ · · 2016-02-16ACS800 Catalogue Related tools and accessories. ... 12 ACS800 Cabinet built single drive 13 ... products

DriveIT Low Voltage AC Drive

ACS800 CatalogueRelated tools and accessories

2 3AFE 64572504 REV E EN 17.10.2003

33AFE 64572504 REV E EN 17.10.2003

Contents

GeneralABB 5

IndustrialIT for drives 5

AC drives 5

ProductsACS800 for AC motors, compact and complete 6 - 7

ACS800 Wall-mounted single drive 8 - 10

ACS800 Free standing single drive 8 - 10

ACS800 Single drive modules 11 - 12

ACS800 Cabinet built single drive 13 - 15

ACS800 4-Quadrant drive 16 - 17

Standard application software 18

Start-up Assistant 19

Adaptive Programming 20

Control SolutionsABB’s ready-made Control Solutions for specific drive applications 21

Centrifuge Control 22

Extruder Control 22

Pump and Fan Control 23

Spinning Control & Traverse Control 24

Crane Drive Control 25

OthersACS800 I/O 26

Control Panel 27

Fieldbus Control 28

Dynamic Braking 29 - 30

Output filters 31 - 32

Programming Tool - DriveAP 33

Integration Tool - DriveOPC 34

Engineering Tool - DriveSize 35

Start-up and Maintenance Tool - DriveWindow 2 36

Start-up and Maintenance Tool - DriveWindow Light 2.1 37

Remote Monitoring Tool 38

Energy saving with ACS800 39

pages

4 3AFE 64572504 REV E EN 17.10.2003

DriveIT Low Voltage AC DriveACS800

53AFE 64572504 REV E EN 17.10.2003

ABBABB is one of the largest technologycompanies in the world with broadindustry knowledge and geographicscope. It has about 133,000 employ-ees in around 100 countries andoccupies a leading position (1, 2 or3) in each industry and productareas it serves.

ABB offers complete industry andprocess specific solutions, fromproducts to turnkey projects inutilities, oil, gas and petrochemicals,manufacturing and consumerindustries, and process industries.ABB offers world-class collaborativebusiness platforms and solutionsbased on IndustrialIT open architec-ture software.

IndustrialIT for drivesAs a key element of its businessstrategy, ABB has committed to abroad program of product develop-ment and positioning under theIndustrial IT umbrella. This initiativeis geared towards increasing stan-dardization of ABB products as the“building blocks” of larger solutions,while building in functionality thatwill allow multiple products tointeract seamlessly as componentsof real-time automation and informa-tion systems.

At the product level ABB's Industrial ITarchitecture ensures that ABBproducts can interoperate perfectly.Only products that satisfy a com-plete list of requirements stipulatedby Industrial IT are certified to bearthe Industrial IT enabled symbol, aspecial mark that indicates that theproduct can be easily integratedinto the Industrial IT architecture, ina “plug & produce” manner.

DriveIT Low Voltage AC DriveACS800

Standardization and an architecturebased on open standards increaseengineering efficiency, speed ofimplementation and quality. Thefinal result is higher productivityand more output from your plant.Through versatile connectivity thedrives made by ABB can be easilyintegrated with different processautomation systems fulfilling therequirements of Industrial IT.

Our DriveIT drive products providethe performance, energy savingsand life extension that the custom-ers have come to expect from ABB.

AC drivesAC drives are used to control thespeed and torque of a standardinduction motor, the workhorse ofthe industry. ABB is a market leaderin both motors and drives world-wide.

AC drive technology extends themotor speed range from zero tohigh above the rated speed, increas-ing the productivity of the drivenprocess. When a low capacity isenough, the drive reduces themachine speed and saves energy.

Accurate speed control of themanufacturing process optimizesthe quality of the end product. TheDirect Torque Control (DTC)developed by ABB has improvedcontrol accuracy by making speedencoders unnecessary.

6 3AFE 64572504 REV E EN 17.10.2003

ACS800up to 2800 kW AC motors,compact and complete.

Common technology fordifferent applicationsOne of the main benefits of theACS800 series is a wide range ofdrive products with commontechnologies. This includes Start-upAssistant, Adaptive Programmingand DTC, common user and pro-cess interfaces, software tools forsizing, commissioning and mainte-nance and common spare parts.

Premium Technology - DTCThe heart of the ACS800 is DTC -Direct Torque Control, its first classmotor control system. The consis-tently excellent performance of theACS800 guarantees that the driveis not the limiting factor in yourprocess.

DTC technology is well proven invarious applications and demandingenvironments guaranteeing the highreliability of the drive.

Start-up AssistantThe ABB AC drives have alwaysbeen top of their class in user-friendliness. The new product seriesbrings a whole new meaning to“user-friendliness”. Thanks to theStart-up Assistant, the commission-ing and tuning of a highperformance drive could not beeasier.

Adaptive ProgrammingThe ACS800 goes one step furthercompared to normal parameterprogramming with the addition ofAdaptive Programming. It is likehaving a small PLC inside yourdrive. Adaptive Programming needsno additional hardware or softwarebut is always there when needed.

Integration and CompactDesignAnything that is required from anAC drive, like EMC and harmonicfilters, is inside the drive, so noextra space or cabling is needed.Furthermore, there is always spaceinside the ACS800 for three optionmodules for I/O extensions,fieldbuses, pulse encoder interfaceor a PC connection.

ACS800 voltage power rangeMotor

[kW]

2800

1900

1450

800

200

110

37

5.5

1.5

1.1

0.55

200 240 380 415 500 690 Supply [V]

73AFE 64572504 REV E EN 17.10.2003

Environmentally soundproductsABB is a signatory to the ICC(International Chamber of Com-merce) Business Charter forSustainable Development and isworking towards fulfilling its re-quirements. ABB AC drives followall 16 ICC principles and the basicfunction of variable speed drivesis to minimize the environmentalimpact by matching the speed ofthe driven machine to the actualneed in the process. This oftenmeans that the environmental loadreduction in the process is ten timesmore than the environmental loadcaused by the manufacture, trans-port and disposal of the drives.

The manufacturing of AC drivescomplies with ISO 14001 standards.

Common software features,please see pages 18 - 20.

Technical specifications for theACS800-01/-02/-04/-07/-17

Mains connection3-Phase supply voltage: U2IN = 208…240 V ± 10%

U3IN = 380…415 V ± 10%U5IN = 380…500 V ± 10%U7IN = 525…690 V ± 10%

Frequency: 48...63 Hz

Power factor: cosϕ1

= 0.98 (fundamental)cosϕ = 0.93...0.95 (total)

Power factor (ACS800-17): cosϕ1

= 1 (fundamental)cosϕ = 0.99 (total)

EfficiencyAt nominal power:

ACS800-0x 98%

ACS800-17 97%

Motor connection3-Phase output voltage: 0...U2IN/U3IN/U5IN//U7IN

Frequency control: 0...±300 Hz0...±120 Hz with du/dt filters

Field weakening point: 8...300 Hz

Motor control software: ABB’s Direct Torque Control (DTC)

Torque control: Torque step rise time:Open loop <5 ms with nominal torqueClosed loop <5 ms with nominal torque

Non-linearity:Open loop ±4% with nominal torqueClosed loop ±1% with nominal torque

Speed control: Static accuracy:Open loop 10% of motor slipClosed loop 0.01% of nominal speed

Dynamic accuracy:Open loop 0.3...0.4%sec. with 100% torque stepClosed loop 0.1...0.2%sec. with 100% torque step

Environmental limitsAmbient temperature:Transportation: -40...+70°CStorage: -40...+70°COperation: -15...+50°C, no frost allowed

40...50°C at reduced output current (1%/1°C).

Operation (ACS800-17): 0...+50°C

40...50°C at reduced output current (1.5%/1°C).Relative humidity: 5 to 95%, no condensation allowed.

Cooling method: Dry clean air

Altitude: 0...1000 m without derating1000...4000 m with derating (690 V units 1000...2000 mwith derating)

8 3AFE 64572504 REV E EN 17.10.2003

ACS800 Wall-mounted single driveACS800-01, up to 110 kW

ACS800 Free standing single driveACS800-02, up to 500 kW

Compact and Completesingle drivesACS800-01 and -02 single drivesoffer you all that you need. Theyare available in IP 21 or IP 55(ACS800-01 only) degrees of protec-tion. The drives up to 110 kW arecompact, wall-mounted ACS800-01drives and from 90 kW up to 500 kWbookshelf-style ACS800-02 driveswith a new innovative free-standingenclosure. The difference betweenthe ACS800-01 and the ACS800-02is the mechanical construction -otherwise the drives are similar.

Fits anywhereBoth ACS800-01 and ACS800-02drives are extremely compactwithout sacrificing user-friendliness.

The ACS800-02 has a unique,extremely compact bookshelfdesign. When using bookshelfmounting, even side-by-side instal-lation is possible. In addition tobookshelf mounting, the ACS800-02offers a possibility for flat typemounting enabling you to optimisethe width or depth depending onyour needs.

Everything insideFrom the smallest ACS800-01 tothe biggest ACS800-02 there is anextensive selection of in-builtfeatures and accessories. Thestandard features include a choke

for harmonic filtering and driveprotection, extensive and flexibleI/O, user-friendly control panel witha Start-up Assistant feature and asilent long-lifetime cooling fan.

If even more features are needed, awide selection of inbuilt options isavailable. An enclosure extensionis also available for the ACS800-02,further enhancing its versatility.

Accessories for theACS800-01 and -02:• Brake chopper• EMC filter / two alternatives:

•EN 61800-3, 2nd environment,unrestricted distribution

•EN 61800-3, 1st environment,restricted distribution

• Analogue and digital I/Oextension modules

• Fieldbus modules• Pulse encoder interface module

Accessories for the ACS800-01:• IP 55

Accessories for the ACS800-02:• Common mode filters for motor

protection

Accessories requiring enclosureextension for the ACS800-02:• Fuse switch• Contactor with emergency stop

pushbutton• 1 or 2 thermistor relays• 3 Pt100 relays• Cable top entry and exit• Customer terminal block

In addition several external acces-sories available like du/dt filter,brake resistor.

Main standard hardwarefeatures:Common in-built features:• IP 21 protection class• Compact design• Harmonic filtering choke inside• Long life time cooling fan and

capacitors• Extensive, programmable I/O• Inputs galvanically isolated• Three I/O and fieldbus extension

slots inside• Alphanumeric, multilingual

control panel with a Start-upAssistant feature

• Large power terminals allowinguse of over sized or aluminiumcable

Additionally in ACS800-02:• Free standing• Two mounting directions as

standard• Very narrow bookshelf design

93AFE 64572504 REV E EN 17.10.2003

Degree of Protection:Degree of Protection:Degree of Protection:Degree of Protection:Degree of Protection:IP 21 (Standard)IP 55 (Optional) for ACS800-01Paint color:Paint color:Paint color:Paint color:Paint color:NCS 1502-Y (RAL 90021/PMS 420C)

Enclosure

Type Nominal No-overload Light-overload Heavy-duty Noise Heat Air flow

ratings use use use level dissipation

I cont.max I max P cont.max I N P N I hd P hd FrameA A kW A kW A kW size dBA W m3/h

Three phase supply voltage 208, 220, 230 or 240 V. The power ratings are valid at nominal voltage (230 V).ACS800-01-0001-2 5.1 6.5 1.1 4.7 0.75 3.4 0.55 R2 62 100 35ACS800-01-0002-2 6.5 8.2 1.5 6.0 1.1 4.3 0.75 R2 62 100 35ACS800-01-0003-2 8.5 10.8 1.5 7.7 1.5 5.7 1.1 R2 62 100 35ACS800-01-0004-2 10.9 13.8 2.2 10.2 2.2 7.5 1.5 R2 62 120 35ACS800-01-0005-2 13.9 17.6 3 12.7 3 9.3 2.2 R2 62 140 35ACS800-01-0006-2 19 24 4 18 4 14 3 R3 62 160 69ACS800-01-0009-2 25 32 5.5 24 5.5 19 4 R3 62 200 69ACS800-01-0011-2 34 46 7.5 31 7.5 23 5.5 R3 62 250 69ACS800-01-0016-2 44 62 11 42 11 32 7.5 R4 62 340 103ACS800-01-0020-2 55 72 15 50 11 37 7.5 R4 62 440 103ACS800-01-0025-2 72 86 18.5 69 18.5 49 11 R5 65 530 168ACS800-01-0030-2 86 112 22 80 22 60 15 R5 65 610 168ACS800-01-0040-2 103 138 30 94 22 69 18.5 R5 65 810 168ACS800-01-0050-2 141 164 37 132 37 97 30 R6 65 1190 405ACS800-01-0060-2 166 202 45 155 45 115 30 R6 65 1190 405ACS800-01-0070-2 202 282 55 184 55 141 37 R6 65 1440 405ACS800-02-0080-2 214 326 55 211 55 170 45 R7 71 2750 540ACS800-02-0100-2 253 404 75 248 75 202 55 R7 71 3350 540ACS800-02-0120-2 295 432 90 290 90 240 1) 55 R7 71 3950 540ACS800-02-0140-2 405 588 110 396 110 316 90 R8 72 5300 1220ACS800-02-0170-2 447 588 132 440 132 340 90 R8 72 6050 1220ACS800-02-0210-2 528 588 160 516 160 370 110 R8 72 6550 1220ACS800-02-0230-2 613 840 160 598 160 480 132 R8 72 7450 1220ACS800-02-0260-2 693 1017 200 679 200 590 2) 160 R8 72 7850 1220ACS800-02-0300-2 720 1017 200 704 200 635 3) 200 R8 72 8300 1220Three phase supply voltage 380, 400 or 415 V. The power ratings are valid at nominal voltage (400 V).ACS800-01-0003-3 5.1 6.5 1.5 4.7 1.5 3.4 1.1 R2 62 100 35ACS800-01-0004-3 6.5 8.2 2.2 5.9 2.2 4.3 1.5 R2 62 120 35ACS800-01-0005-3 8.5 10.8 3 7.7 3.0 5.7 2.2 R2 62 140 35ACS800-01-0006-3 10.9 13.8 4 10.2 4.0 7.5 3.0 R2 62 160 35ACS800-01-0009-3 13.9 17.6 5.5 12.7 5.5 9.3 4.0 R2 62 200 35ACS800-01-0011-3 19 24 7.5 18 7.5 14 5.5 R3 62 250 69ACS800-01-0016-3 25 32 11 24 11 19 7.5 R3 62 340 69ACS800-01-0020-3 34 46 15 31 15 23 11 R3 62 440 69ACS800-01-0025-3 44 62 22 41 18.5 32 15 R4 62 530 103ACS800-01-0030-3 55 72 30 50 22 37 18.5 R4 62 610 103ACS800-01-0040-3 72 86 37 69 30 49 22 R5 65 810 168ACS800-01-0050-3 86 112 45 80 37 60 30 R5 65 990 168ACS800-01-0060-3 103 138 55 94 45 69 37 R5 65 1190 168ACS800-01-0070-3 141 164 75 132 55 97 45 R6 65 1440 405ACS800-01-0100-3 166 202 90 155 75 115 55 R6 65 1940 405ACS800-01-0120-3 202 282 110 184 90 141 75 R6 65 2310 405ACS800-02-0140-3 206 326 110 202 110 163 90 R7 71 3050 540ACS800-02-0170-3 248 404 132 243 132 202 110 R7 71 3700 540ACS800-02-0210-3 289 432 160 284 160 240 1) 132 R7 71 4300 540ACS800-02-0260-3 445 588 200 440 200 340 160 R8 72 6600 1220ACS800-02-0320-3 521 588 250 516 250 370 200 R8 72 7200 1220ACS800-02-0400-3 602 840 315 590 315 477 250 R8 72 8100 1220ACS800-02-0440-3 693 1017 355 679 355 590 2) 315 R8 72 8650 1220ACS800-02-0490-3 720 1017 400 704 400 635 3) 355 R8 72 9100 1220

Cooling air flowrequirements

H1 = Height with cable connection boxH2 = Height without cable connection boxW1 = Width of the standard unitW2 = Width with enclosure extensionN/A = not availableA) The dimensions apply to bookshelf

mounting. In flat type mounting thewidth and depth change places.

B) With enclosure extension the depth isincreased by 25 mm due to the switchfuse handle.

C) ACS800-01 without cable connection boxdoes not fulfill IP 21 requirements.

*) Weights are for the basic configuration with switch fuse, but without contactor and other options.

Type IP 21 IP 55

H1 H2 W1 W2 Depth Weight Weight with H1 W1 Depth Weightmm mm mm mm mm kg enclosure mm mm mm kg

extension *) kg

R2 405 370 C) 165 N/A 226 9 N/A 528 263 242 16R3 471 420 C) 173 N/A 265 12 N/A 528 263 273 18R4 606 490 C) 240 N/A 274 26 N/A 774 377 278 32R5 739 602 C) 265 N/A 286 37 N/A 775 377 308 50R6 880 700 C) 300 N/A 400 67 N/A 923 420 427 77R7 1507 N/A 250 A) 602 520 A) B) 110 234 N/A N/A N/A N/AR8 2024 N/A 347 A) 793 617 A) B) 240 450 N/A N/A N/A N/A

10 3AFE 64572504 REV E EN 17.10.2003




Three phase supply voltage 380, 400, 415, 440, 460, 480 or 500 V. The power ratings are valid at nominal voltage (500 V).ACS800-01-0004-5 4.9 6.5 2.2 4.5 2.2 3.4 1.5 R2 62 120 35ACS800-01-0005-5 6.2 8.2 3 5.6 3.0 4.2 2.2 R2 62 140 35ACS800-01-0006-5 8.1 10.8 4 7.7 4.0 5.6 3.0 R2 62 160 35ACS800-01-0009-5 10.5 13.8 5.5 10 5.5 7.5 4.0 R2 62 200 35ACS800-01-0011-5 13.2 17.6 7.5 12 7.5 9.2 5.5 R2 62 250 35ACS800-01-0016-5 19 24 11 18 11 13 7.5 R3 62 340 69ACS800-01-0020-5 25 32 15 23 15 18 11 R3 62 440 69ACS800-01-0025-5 34 46 18.5 31 18.5 23 15 R3 62 530 69ACS800-01-0030-5 42 62 22 39 22 32 18.5 R4 62 610 103ACS800-01-0040-5 48 72 30 44 30 36 22 R4 62 810 103ACS800-01-0050-5 65 86 37 61 37 50 30 R5 65 990 168ACS800-01-0060-5 79 112 45 75 45 60 37 R5 65 1190 168ACS800-01-0070-5 96 138 55 88 55 69 45 R5 65 1440 168ACS800-01-0100-5 124 164 75 115 75 88 55 R6 65 1940 405ACS800-01-0120-5 157 202 90 145 90 113 75 R6 65 2310 405ACS800-01-0140-5 180 282 110 163 110 141 90 R6 65 2810 405ACS800-02-0170-5 196 326 132 192 132 162 110 R7 71 3050 540ACS800-02-0210-5 245 384 160 240 160 192 132 R7 71 3850 540ACS800-02-0260-5 289 432 200 284 200 224 160 R7 71 4550 540ACS800-02-0320-5 440 588 250 435 250 340 200 R8 72 6850 1220ACS800-02-0400-5 515 588 315 510 315 370 250 R8 72 7850 1220ACS800-02-0440-5 550 840 355 545 355 490 315 R8 72 7600 1220ACS800-02-0490-5 602 840 400 590 400 515 2) 355 R8 72 8100 1220ACS800-02-0550-5 684 1017 450 670 450 590 2) 400 R8 72 9100 1220ACS800-02-0610-5 718 1017 500 704 500 632 3) 450 R8 72 9700 1220Three phase supply voltage 525, 575, 600, 660 or 690 V. The power ratings are valid at nominal voltage (690 V).ACS800-01-0011-7 13 14 11 11.5 7.5 8.5 5.5 R4 62 300 103ACS800-01-0016-7 17 19 15 15 11 11 7.5 R4 62 340 103ACS800-01-0020-7 22 28 18.5 20 15 15 11 R4 62 440 103ACS800-01-0025-7 25 38 22 23 18.5 19 15 R4 62 530 103ACS800-01-0030-7 33 44 30 30 22 22 18.5 R4 62 610 103ACS800-01-0040-7 36 54 30 34 30 27 22 R4 62 690 103ACS800-01-0050-7 51 68 45 46 37 34 30 R5 65 840 168ACS800-01-0060-7 57 84 55 52 45 42 37 R5 65 1010 168ACS800-01-0070-7 79 104 75 73 55 54 45 R6 65 1220 405ACS800-01-0100-7 93 124 90 86 75 62 55 R6 65 1650 405ACS800-01-0120-7 113 172 110 108 90 86 75 R6 65 1960 405


Nominal Ratings:Icont.max: rated current available continuously withoutoverloadability at 40°C.

Imax: maximum output current. Available for 10 s atstart, otherwise as long as allowed by drivetemperature. Note: max. motor shaft power is150% Phd.

Typical Ratings:No-overload usePcont.max: typical motor power in no-overload use.

Light-overload useIN: continuous current allowing 110% IN for1min/ 5 min at 40°C.PN: typical motor power in light-overload use.

Heavy-duty useIhd: continuous current allowing 150% Ihd for1min/ 5 min at 40°C.

Phd: typical motor power in heavy-duty use.

The current ratings are the same regardless of thesupply voltage within one voltage range.

The ratings apply at 40°C ambient temperature. At higher temperatures (up to 50°C) the derating is1%/1°C.

Notes:1) 50% overload available if Tamb < 25°C.

If Tamb = 40°C, max overload for 1 min is 37%.

2) 50% overload available if Tamb < 30°C.If Tamb = 40°C, max overload for 1 min is 40%.


4) Higher value available if output frequency is above41Hz.

113AFE 64572504 REV E EN 17.10.2003

ACS800 Single drive modulesACS800-04, up to 560 kW

Main standard hardwarefeatures:• Optimised design for cabinet

assembly• EMC compliant module• Modular design allowing wide

variety of variants• Easy access to power terminals• Easy access and free location of

I/O terminals• Compact design• Harmonic filtering choke inside• Long life time cooling fan and

capacitors• Extensive, programmable I/O• Inputs galvanically isolated• Three I/O and fieldbus extension

slots inside• Large power terminals allowing

use of over sized or aluminiumcable

Optimized constructionThe ACS800-04 has several benefitsthat make it the optimal choice forpanel builders.

No special EMC proof cabinets areneeded. In ACS800-04 drives within-built EMC filtering, both radiatedand conducted emissions arerestricted to EN 61800-3 limitswithout the need for any extrahardware.

Innovative fixing mechanics whichminimize the number of bolts facil-itate the attachment of the drivemodule. Fixing of the control unitand control panel is easy thanks tothe DIN rail mounting and new typeof mounting platform.

The compact size with plenty ofbuilt-in options minimizes bothspace requirements and the amountof assembly work needed.

Easy cablingThe easily accessible power termi-nals with plenty of space aroundthem make power cabling for theACS800-04 easy. Moreover, aseparate control unit enables easyaccess to the I/O terminals. Thecontrol unit can be optimally sitedinside the cabinet to enable accessto the I/O terminals without need-ing to open the drive module.

The need for busbars and cables inthe cabinet has been minimized byhaving the incoming power termi-nals on the top of the module. Thisenables use of the optimal cablingroute.

Maximised flexibilityThanks to modular design ACS800-04 offers wide variety of installationpossibilities. Both bookshelfmounting for optimised width andflat type mounting for optimiseddepth are available.

Accessories for the ACS800-04In-built options:• Brake chopper• EMC filter:

• EN 61800-3, 2nd environment,unrestricted distribution

• Common mode filters formotor protection

• Analogue and digital I/Oextension modules

• Fieldbus modules• Pulse encoder interface module• Various output busbar options

(ACS800-04M)• Flat type cabling pedestal

enabling sideways mounting(ACS800-04M)

Other options:• Control panel and mounting

platform

There are several other possibilitiesto adapt the drive module tocustomer needs as well. As examplesare possibility of wall or floormounting and possibility of chang-ing the outputs from left to right.

Naturally also the adaptive softwareand other standard and optionalfeatures of the ACS800 series areavailable.

12 3AFE 64572504 REV E EN 17.10.2003

*) coming with every unit

Type Height Width Depthmm mm mm

RDCU control unit *) 282 126 41

Degree of Protection:Degree of Protection:Degree of Protection:Degree of Protection:Degree of Protection:IP 00Paint color:Paint color:Paint color:Paint color:Paint color:NCS 1502-Y (RAL 90021/PMS 420C)

EnclosureNominal Ratings:Icont.max: rated current available continuously withoutoverloadability at 40°C.

IMAX: maximum output current. Available for 10 s atstart, otherwise as long as allowed by drive tempe-rature. Note: max. motor shaft power is 150% Phd.

Typical Ratings:No-overload usePcont.max: typical motor power in no-overload use.




The current ratings are the same regardless of thesupply voltage within one voltage range.

The ratings apply at 40°C ambient temperature.At higher temperatures (up to 50°C) the derating is1%/1°C.




Three phase supply voltage 208, 220, 230 or 240 V. The power ratings are valid at nominal voltage (230 V).ACS800-04/04M-0080-2 214 326 55 211 55 170 45 R7 71 2750 540ACS800-04/04M-0100-2 253 404 75 248 75 202 55 R7 71 3350 540ACS800-04/04M-0120-2 295 432 90 290 90 240 1) 55 R7 71 3950 540ACS800-04/04M-0140-2 405 588 110 396 110 316 90 R8 72 5300 1220ACS800-04/04M-0170-2 447 588 132 440 132 340 90 R8 72 6050 1220ACS800-04/04M-0210-2 528 588 160 516 160 370 110 R8 72 6550 1220ACS800-04/04M-0230-2 613 840 160 598 160 480 132 R8 72 7450 1220ACS800-04/04M-0260-2 693 1017 200 679 200 590 2) 160 R8 72 7850 1220ACS800-04/04M-0300-2 720 1017 200 704 200 635 3) 200 R8 72 8300 1220Three phase supply voltage 380, 400 or 415 V. The power ratings are valid at nominal voltage (400 V).ACS800-04/04M-0140-3 206 326 110 202 110 163 90 R7 71 3050 540ACS800-04/04M-0170-3 248 404 132 243 132 202 110 R7 71 3700 540ACS800-04/04M-0210-3 289 432 160 284 160 240 1) 132 R7 71 4300 540ACS800-04/04M-0260-3 445 588 200 440 200 340 160 R8 72 6600 1220ACS800-04/04M-0320-3 521 588 250 516 250 370 200 R8 72 7200 1220ACS800-04/04M-0400-3 602 840 315 590 315 477 250 R8 72 8100 1220ACS800-04/04M-0440-3 693 1017 355 679 355 590 2) 315 R8 72 8650 1220ACS800-04/04M-0490-3 720 1017 400 704 400 635 3) 355 R8 72 9250 1220Three phase supply voltage 380, 400, 415, 440, 460, 480 or 500 V. The power ratings are valid at nominal voltage (500 V).ACS800-04/04M-0170-5 196 326 132 192 132 162 110 R7 71 3050 540ACS800-04/04M-0210-5 245 384 160 240 160 192 132 R7 71 3850 540ACS800-04/04M-0260-5 289 432 200 284 200 224 160 R7 71 4550 540ACS800-04/04M-0320-5 440 588 250 435 250 340 200 R8 72 6850 1220ACS800-04/04M-0400-5 515 588 315 510 315 370 250 R8 72 7850 1220ACS800-04/04M-0440-5 550 840 355 545 355 490 315 R8 72 7600 1220ACS800-04/04M-0490-5 602 840 400 590 400 515 2) 355 R8 72 8100 1220ACS800-04/04M-0550-5 684 1017 450 670 450 590 2) 400 R8 72 9100 1220ACS800-04/04M-0610-5 718 1017 500 704 500 632 3) 450 R8 72 9700 1220Three phase supply voltage 525, 575, 600, 660 or 690 V. The power ratings are valid at nominal voltage (690 V).ACS800-04/04M-0140-7 134 190 132 125 110 95 90 R7 71 2800 540ACS800-04/04M-0170-7 166 263 160 155 132 131 110 R7 71 3750 540ACS800-04/04M-0210-7 166/203 4) 294 160 165/195 4) 160 147 132 R7 71 4250 540ACS800-04/04M-0260-7 175/230 4) 326 160/200 4) 175/212 4) 200 4) 163 160 R7 71 4800 540ACS800-04/04M-0320-7 315 433 315 290 250 216 200 R8 72 6150 1220ACS800-04/04M-0400-7 353 548 355 344 315 274 250 R8 72 6650 1220ACS800-04/04M-0440-7 396 656 400 387 355 328 315 R8 72 7400 1220ACS800-04/04M-0490-7 445 775 450 426 400 387 355 R8 72 8450 1220ACS800-04/04M-0550-7 488 853 500 482 450 426 400 R8 72 8300 1220ACS800-04/04M-0610-7 560 964 560 537 500 482 450 R8 72 9750 1220






4) Higher value available if output frequency isabove 41Hz.

Width with cable connection plate for output cables.

Bookshelf design

Flat type design

Type Height Width Depth Weightmm mm mm kg

R7 1121 426 467 100R8 1558 571 564 205

Type Height Width Depth Weightmm mm mm kg

R7 1152 631 259 100R8 1589 779 356 205

133AFE 64572504 REV E EN 17.10.2003

ACS800 Cabinet built single driveACS800-07, up to 2800 kW

Customised solutionsACS800-07 is a cabinet built singledrive designed for industrial appli-cations. It covers a wide power rangeand is very compact, the 2800 kWdrive is only 3.2 meters wide. It isavailable with IP 21, IP 22, IP 42,IP 54 and IP 54R protection classes.

The ACS800-07 offers a wide varietyof standardized configurations toadapt to different applicationrequirements, from line contactor tothe prevention of unexpected motorstart, or ATEX approved motorprotection.

If your application requires more,ABB’s application engineeringservices can add special featuresto the standard product such as anadditional cabinet for customerspecific devices to ensure exactsuitability for the application.

Smart module conceptThe drives up to 500 kW are basedon a compact single module includ-ing rectifier and inverter.

Larger drives consist of separaterectifier and inverter modules, whichhave plug-in power connectorsproviding easy maintenance and

redundancy with parallel con-nected units. The rectifier moduleprovides 6- or 12-pulse operationas standard.

Extensive range of featuresThe ACS800-07 has an extensiverange of inbuilt features and acces-sories. Typical accessory choicesinclude extended I/O and fieldbusoptions, line contactor, EMC filter-ing, common mode filtering anddu/dt (voltage rise) filtering, allmountable within the singlecabinet.

Accessories for the ACS800-07:• Analogue and digital I/O exten-

sion modules• ATEX approved motor protection• Braking chopper and resistor• Cabinet heater• Common mode filters for motor

protection• Customer terminal block• Du/dt filters• Earth fault monitoring for un-

earthed network• EMC filter• Fieldbus modules• IP 22, 42, 54 or 54R enclosure

classes• Line contactor with emergency

stop push button• Line fuse switch (frames nxR8i)• Output for fan motor• Prevention of unexpected motor

start• Pulse encoder interface module• Top entry and exit of cables• 1 or 2 thermistor relays• 3, 5 or 8 Pt100 relays

Plus tailor made accessories throughABB’s application engineering.

Main standard hardware features• Compact design• IP 21 protection class• Inbuilt harmonic filtering choke• Fuse switch (frames R6-R8)• Main switch (frames nxR8i)• Extensive, programmable I/O,• 6- or 12-pulse operation (frames

nxR8i)• Long lifetime cooling fan and

capacitors• Inputs galvanically isolated• I/O and fieldbus extension slots

inside• Alphanumeric multilingual

control panel with Start-upAssistant feature

14 3AFE 64572504 REV E EN 17.10.2003



I cont.max I max P cont.max I N P N I hd P hd FrameA A kW A kW A kW size dBA kW m3/h

Three phase supply voltage 380, 400 or 415 V. The power ratings are valid at nominal voltage (400 V).ACS800-07-0070-3 141 164 75 132 55 97 45 R6 65 1.44 405ACS800-07-0100-3 166 202 90 155 75 115 55 R6 65 1.94 405ACS800-07-0120-3 202 282 110 184 90 141 75 R6 65 2.31 405ACS800-07-0140-3 206 326 110 202 110 163 90 R7 71 3.05 540ACS800-07-0170-3 248 404 132 243 132 202 110 R7 71 3.70 540ACS800-07-0210-3 289 432 160 284 160 240 1) 132 R7 71 4.30 540ACS800-07-0260-3 445 588 200 440 200 340 160 R8 72 6.60 1220ACS800-07-0320-3 521 588 250 516 250 370 200 R8 72 7.20 1220ACS800-07-0400-3 602 840 315 590 315 477 250 R8 72 8.10 1220ACS800-07-0440-3 693 1017 355 679 355 590 2) 315 R8 72 8.65 1220ACS800-07-0490-3 720 1017 400 704 400 635 3) 355 R8 72 9.10 1220ACS800-07-0610-3 879 1313 500 844 500 657 400 1xD4 + 2xR8i 73 13.0 3120ACS800-07-0770-3 1111 1519 630 1067 630 830 450 2xD4 + 2xR8i 74 17.7 3840ACS800-07-0870-3 1255 1876 710 1204 710 938 500 2xD4 + 2xR8i 74 18.9 3840ACS800-07-1030-3 1452 1987 800 1394 800 1086 630 2xD4 + 2xR8i 74 25.5 3840ACS800-07-1230-3 1770 2648 1000 1700 1000 1324 710 2xD4 + 3xR8i 75 28.0 5040ACS800-07-1540-3 2156 2950 1200 2070 1200 1612 900 3xD4 + 3xR8i 76 43.7 5760ACS800-07-1850-3 2663 3983 1450 2557 1450 1992 1120 3xD4 + 4xR8i 76 49.1 6960Three phase supply voltage 380, 400, 415, 440, 460, 480 or 500 V. The power ratings are valid at nominal voltage (500 V).ACS800-07-0100-5 124 164 75 115 75 88 55 R6 65 1.94 405ACS800-07-0120-5 157 202 90 145 90 113 75 R6 65 2.31 405ACS800-07-0140-5 180 282 110 163 110 141 90 R6 65 2.81 405ACS800-07-0170-5 196 326 132 192 132 162 110 R7 71 3.05 540ACS800-07-0210-5 245 384 160 240 160 192 132 R7 71 3.85 540ACS800-07-0260-5 289 432 200 284 200 224 160 R7 71 4.55 540ACS800-07-0320-5 440 588 250 435 250 340 200 R8 72 6.85 1220ACS800-07-0400-5 515 588 315 510 315 370 250 R8 72 7.85 1220ACS800-07-0440-5 550 840 355 545 355 490 315 R8 72 7.60 1220ACS800-07-0490-5 602 840 400 590 400 515 2) 355 R8 72 8.10 1220ACS800-07-0550-5 684 1017 450 670 450 590 2) 400 R8 72 9.10 1220ACS800-07-0610-5 718 1017 500 704 500 632 3) 450 R8 72 9.70 1220ACS800-07-0760-5 883 1318 630 847 630 659 500 1xD4 + 2xR8i 73 14.4 3120ACS800-07-0910-5 1050 1521 710 1008 710 784 560 2xD4 + 2xR8i 74 18.6 3840ACS800-07-1090-5 1258 1880 900 1208 900 940 630 2xD4 + 2xR8i 74 21.1 3840ACS800-07-1210-5 1372 1989 1000 1317 1000 1025 710 2xD4 + 2xR8i 74 26.6 3840ACS800-07-1540-5 1775 2653 1250 1704 1200 1326 900 2xD4 + 3xR8i 75 31.5 5040ACS800-07-1820-5 2037 2953 1450 1956 1400 1522 1120 3xD4 + 3xR8i 76 48.1 5760ACS800-07-2310-5 2670 3990 1900 2563 1850 1995 1400 3xD4 + 4xR8i 76 57.0 6960Three phase supply voltage 525, 575, 600, 660 or 690 V. The power ratings are valid at nominal voltage (690 V).ACS800-07-0070-7 79 104 75 73 55 54 45 R6 65 1.22 405ACS800-07-0100-7 93 124 90 86 75 62 55 R6 65 1.65 405ACS800-07-0120-7 113 172 110 108 90 86 75 R6 65 1.96 405ACS800-07-0140-7 134 190 132 125 110 95 90 R7 71 3.00 540ACS800-07-0170-7 166 263 160 155 132 131 110 R7 71 3.75 540ACS800-07-0210-7 166/203 4) 294 160 165/195 4) 160 147 132 R7 71 4.45 540ACS800-07-0260-7 175/230 4) 326 160/200 4) 175/212 4) 200 163 160 R7 71 4.80 540ACS800-07-0320-7 315 433 315 290 250 216 200 R8 72 6.15 1220ACS800-07-0400-7 353 548 355 344 315 274 250 R8 72 6.65 1220ACS800-07-0440-7 396 656 400 387 355 328 315 R8 72 7.40 1220ACS800-07-0490-7 445 775 450 426 400 387 355 R8 72 8.45 1220ACS800-07-0550-7 488 853 500 482 450 426 400 R8 72 8.30 1220ACS800-07-0610-7 560 964 560 537 500 482 450 R8 72 9.75 1220ACS800-07-0750-7 628 934 630 603 630 467 500 1xD4 + 2xR8i 73 15.3 3120ACS800-07-0870-7 729 1084 710 700 710 542 560 1xD4 + 2xR8i 73 18.5 3120ACS800-07-1060-7 885 1318 800 849 800 659 630 1xD4 + 2xR8i 73 19.4 3120ACS800-07-1160-7 953 1419 900 914 900 710 710 2xD4 + 2xR8i 74 23.9 3840ACS800-07-1500-7 1258 1874 1200 1208 1200 937 900 2xD4 + 3xR8i 75 29.2 5040ACS800-07-1740-7 1414 2107 1400 1358 1400 1053 1000 2xD4 + 3xR8i 75 35.4 5040ACS800-07-2120-7 1774 2643 1700 1703 1700 1322 1250 2xD4 + 4xR8i 76 42.2 6240ACS800-07-2320-7 1866 2780 1900 1792 1800 1390 1400 3xD4 + 4xR8i 76 56.5 6960ACS800-07-3190-7 2665 3970 2600 2559 2500 1985 1900 3xD4 + 6xR8i 78 68.3 9360ACS800-07-3490-7 2770 4127 2800 2659 2700 2063 2100 4xD4 + 6xR8i 78 91.2 10080


153AFE 64572504 REV E EN 17.10.2003

Nominal Ratings:Icont.max: rated current available continuouslywithout overloadability at 40°C.

Imax: maximum output current. Available for10 s at start, otherwise as long as allowed bydrive temperature. Note: max. motor shaftpower is 150% Phd.

Typical Ratings:No-overload usePcont.max: typical motor power in no-overloaduse.




The current ratings are the same regardlessof the supply voltage within one voltagerange.

The ratings apply at 40°C ambient temperature.At higher temperatures (up to 50°C) thederating is 1%/1°C.

DegrDegrDegrDegrDegree of Pree of Pree of Pree of Pree of Protection:otection:otection:otection:otection:IP 21 (Standard)IP 22, IP 42, IP 54, IP54R (Optional)Paint color:Paint color:Paint color:Paint color:Paint color:Light beige RAL 7035 semi-gloss

Enclosure





4) Higher value available if output frequency isabove 41Hz.

5) 630 mm for types ACS800-07-0120-3 and0140-5 if equipped with du/dt filter.

Frame Width *) Width with line Height *) Height *) Depth *) Depth top Weight Weight (kg) withsize fuse switch *) IP 21/22/42 IP 54 entry/exit *) kg line fuse switch

R6 - 430 5) 2130 2315 646 646 - 300R7 - 830 2130 2315 646 646 - 400R8 - 830 2130 2315 646 646 - 5001xD4 + 2xR8i 1330 1730 2130 2315 646 730 890 11002xD4 + 2xR8i 1630 2030 2130 2315 646 730 1200 14102xD4 + 3xR8i 1830 2230 2130 2315 646 730 1350 15602xD4 + 4xR8i 2230 2630 2130 2315 646 730 1680 18903xD4 + 3xR8i 2030 2630 2130 2315 646 730 1540 18003xD4 + 4xR8i 2430 3030 2130 2315 646 730 1870 21303xD4 + 6xR8i 2830 3430 2130 2315 646 730 2170 24304xD4 + 6xR8i 3230 4030 2130 2315 646 730 2520 2940

*) mm

16 3AFE 64572504 REV E EN 17.10.2003

ACS800 4-Quadrant driveAir cooled regenerative drive.ACS800-17, up to 1120 kW

Complete 4-Quadrant driveThe high performance ACS800-174-Quadrant drive allows full powerflow in motoring and generating.Transition between modes is fastdue to the ultrafast DTC controlmethod. Stepping from Pn to -Pn orvice versa takes only few millisec-onds. No dead time in transition isneeded. The drive gives full outputvoltage and even more. Outputvoltage can be boosted, whichmeans that 100% output voltage isavailable even when the inputvoltage is 90%.

Friendly but robust powerlinePower companies set limits for thepermissible harmonic content ofcurrent and voltage in order toprevent damage to equipment in thesame environment. The ACS800-17removes low order harmonics withline converter DTC control and highorder harmonics with an LCL filter.The result is very clean power for6, 12, 18 and 24 pulse rectifiersolutions. The ultrafast DTC caneven compensate for fast variationsin line voltage. There is no risk ofcomponent damage due to voltagedrops as in thyristor-based rectifiersin AC and DC drives.

Energy savingsMost of the motor drive costs areenergy costs. Often the investmentis only a small fraction of totalcosts. Compared with the otherbraking methods like mechanicaland resistor braking, the energysavings can be significant. Brakingresistors also take up installationspace and the handling of wasteheat can be a problem.

Easy and flexibleThe standard software contains theAdaptive Programming feature thatenables the user to make smallmodifications to the software. Othersoftware alternatives are alsoavailable for special applications.There are two features that facilitatecommissioning: the line converter isa plug and play product, so nosettings are needed. The motorinverter parameters can be easilyadjusted from control panel withthe new interactive software, Start-up Assistant.

Excellent supply sidefeaturesThe unique DTC/LCL filter features:• Fundamental power factor unity• Extremely low current and

voltage harmonics• Very small commutating notches

DTC type control has severaladvantages:• Ultra-fast response to changes• No fixed switching frequency,

resonating risk avoided• Switching only when needed,

less switching stress

Other features resulting fromthe DTC’s high stability:• Needs no tuning according to

grid inductance• Plug and play line inverter

LCL filterMotor

inverter

Lineinverter(rectifier)

Motor

ACS800 main modules

173AFE 64572504 REV E EN 17.10.2003

Excellent motor sidefeaturesThe active line rectifier togetherwith DTC ensures robust behavioureven in demanding conditions.• Torque is always stable even

with unstable net voltage• Excellent line voltage dip proof

operation• Extremely fast and smooth

operation in motoring-regenerating-motoring transitions

The motor converter uses thestandard ACS800 DTC motor con-trol. This ultrafast control loopenables fast responses to load andline voltage changes. The adjustableDC voltage boost function makes itpossible to shift the field weakeningpoint to higher frequencies. In manycases this feature enables a one sizesmaller motor to be selected.

Notes:1) Cabinet height is 2130 mm, 2072 mm for IP 54R2) An additional 400 mm is required in frame size R11 with top exits

An additional 600 mm is required in frame size R12 with top exitsCabinet depth is 731 mm

Type I cont max P cont max I_4/5 min I_1/5 min I_50/60 s I_10/60 s Frame Height 1) Width 2) Weight Noise Ploss Air flow

I max size levelA kW A (AC) A (AC) A (AC) A (AC) mm mm kg dB kW m3/h

Three phase supply voltage 380, 400 or 415 V. The power ratings are valid at nominal voltage (400 V).ACS800-17-0120-3 178 90 147 221 147 294 R7i 2130 730 305 63 4.1 1920ACS800-17-0185-3 259 132 194 291 178 356 R8i 2130 1230 625 63 6.0 3650ACS800-17-0225-3 312 160 234 351 216 432 R8i 2130 1230 625 63 7.3 3650ACS800-17-0265-3 379 200 284 426 260 520 R8i 2130 1230 625 63 8.9 3650ACS800-17-0335-3 474 250 356 533 316 632 R9i 2130 1230 655 63 11.2 3650ACS800-17-0405-3 576 315 432 648 395 790 R9i 2130 1230 655 63 13.9 3650ACS800-17-0630-3 907 500 680 1020 600 1200 R11i 2130 3630 1490 68 22.0 7280ACS800-17-0765-3 1094 630 821 1231 751 1502 R11i 2130 3630 1490 68 27.2 7280ACS800-17-0935-3 1336 710 1002 1503 901 1802 R12i 2130 4630 2530 71 31.7 10330ACS800-17-1125-3 1624 900 1218 1827 1126 2252 R12i 2130 4630 2530 71 39.3 10330Three phase supply voltage 380, 400, 415, 440, 460, 480 or 500 V. The power ratings are valid at nominal voltage (500 V).

ACS800-17-0100-5 112 75 84 126 84 168 R6i 2130 730 305 63 3.4 1920ACS800-17-0140-5 164 110 135 203 135 270 R7i 2130 730 305 63 4.9 1920ACS800-17-0215-5 246 160 185 277 164 328 R8i 2130 1230 625 63 7.2 3650ACS800-17-0255-5 295 200 221 332 200 400 R8i 2130 1230 625 63 8.8 3650ACS800-17-0325-5 368 250 276 414 240 480 R8i 2130 1230 625 63 11.1 3650ACS800-17-0395-5 448 315 336 504 300 600 R9i 2130 1230 655 63 13.7 3650ACS800-17-0495-5 565 400 424 636 365 730 R9i 2130 1230 655 63 17.4 3650ACS800-17-0770-5 887 630 665 998 570 1140 R11i 2130 3630 1490 68 27.3 7280ACS800-17-0935-5 1073 710 805 1208 694 1388 R11i 2130 3630 1490 68 31.7 7280ACS800-17-1090-5 1263 900 947 1421 855 1710 R12i 2130 4630 2530 71 38.9 10330ACS800-17-1385-5 1593 1120 1195 1793 1040 2080 R12i 2130 4630 2530 71 48.7 10330Three phase supply voltage 525, 575, 600, 660 or 690 V. The power ratings are valid at nominal voltage (690 V).

ACS800-17-0205-7 176 160 132 198 127 254 R8i 2130 1230 625 63 7.2 3650ACS800-17-0255-7 210 200 158 236 150 300 R8i 2130 1230 625 63 8.8 3650ACS800-17-0315-7 264 250 198 297 179 358 R8i 2130 1230 625 63 10.9 3650ACS800-17-0375-7 310 315 233 349 225 450 R9i 2130 1230 655 63 13.4 3650ACS800-17-0485-7 410 400 308 461 265 530 R9i 2130 1230 655 63 17.2 3650ACS800-17-0750-7 630 630 473 709 428 856 R11i 2130 3630 1730 68 27.0 7280ACS800-17-0900-7 755 710 566 849 504 1008 R11i 2130 3630 1730 68 31.3 7280ACS800-17-1045-7 874 900 656 983 641 1282 R12i 2130 4630 2530 71 38.1 10330ACS800-17-1385-7 1156 1120 867 1301 755 1510 R12i 2130 4630 2530 71 48.7 10330

Nominal ratings 150% duty cycle 200% duty cycle Information for units and cabinets

In moderate voltage drops thecontrol can maintain full DC volt-age and the motors get full power.In heavy voltage drops powercannot be obtained from the line,but the drive can be kept ready toproduce power immediately whenvoltage returns. The time betweenmaximum motoring and regenerat-ing power is in the range ofmilliseconds.

Dimensions limit the number of options in frames R6 / R7 / R8 / R9.

6 pulse rectifier

Transformer and cabling simple

Current very distorted >Ithd 30%

12 pulse rectifier

Transformer and cablingcomplicated

Current distorted >Ithd 12%

18 pulse rectifier

Transformer and cablingcomplicated

Current wave form good >Ithd 6%

ACS800-17

Transformer and cabling simple

Current wave form best Ithd 4%

Degree of Protection:Degree of Protection:Degree of Protection:Degree of Protection:Degree of Protection:IP 21 (Standard)IP 22, IP 42, IP 54R (Optional)Paint color:Paint color:Paint color:Paint color:Paint color:Light beige RAL 7035 semi-gloss

Enclosure

Alternatives in reducing line harmonics

18 3AFE 64572504 REV E EN 17.10.2003

Standard application software

Based on the Direct Torque Controltechnology, the ACS800 offers highlyadvanced features as standard.ACS800 standard application soft-ware provides solution virtually toall AC drives applications.

The standard applicationmacrosThe ACS800 features built-in, pre-programmed application macros forconfiguration of such parameters asinputs, outputs and signal process-ing.• FACTORY SETTINGS for basic

industrilal applications• HAND/AUTO CONTROL for

local and remote operation• PID CONTROL for closed loop

processes• SEQUENTIAL CONTROL for

repetitive cycles• TORQUE CONTROL for processes

where torque control is required• USER MACRO 1 & 2 for user’s

own parameter settings

Software featuresA complete set of standard softwarefeatures offers premium functional-ity and flexibility.• Accurate speed control• Accurate torque control without

speed feedback• Adaptive Programming• Automatic reset• Automatic start• Constant speeds• Controlled torque at zero speed• DC hold• DC Magnetizing• Diagnostics• Flux braking• Flux optimization• IR compensation• Master/follower control• Mechanical brake control• Motor identification• Parameter lock• Power loss ride-through• Process PID control• Programmable I/O• Scalar control• Speed controller tuning• Start-up Assistant• Trim function• User-selectable acceleration and

decelaration ramps

Pre-programmed protectionfunctionsA wide feature range providesprotection for the drive, motor andthe process.• Ambient temperature• DC overvoltage• DC undervoltage• Drive temperature• Input phase loss• Overcurrent• Power limits• Short circuit

Programmable protectionfunctions• Adjustable power limits• Control signal supervision• Critical frequencies lock-out• Current and torque limits• Earth fault protection• External fault• Motor phase loss• Motor stall protection• Motor thermal protection• Motor underload protection• Panel loss

193AFE 64572504 REV E EN 17.10.2003

READY TO STARTREADY TO START

L <- 0.0 rpm 0** INFORMATION **Press FUNC to startguided motor set up

Basic set upLANGUAGE ?[ENGLISH]Select(arrows)+ENTER

Motor set upMOTOR NOM CURRENT ?0 APress FUNC for info

Start-up AssistantThe easy way of commissioning.

ABB AC drives have always beentop of their class in user- friendli-ness. The new ACS800 AC drivebrings a whole new meaning to“user-friendliness”. Thanks to theStart-up Assistant, the commission-ing and tuning of a highperformance drive could not beeasier.

Faster and easiercommissioningWhen you turn on your drive forthe first time the Start-up Assistantactively guides you through thecommissioning procedure. You donot need to worry which param-eters should be set, the Start-upAssistant does that.

To ensure a convenient commis-sioning procedure the Start-upAssistant speaks 14 different lan-guages. It asks for motor nominalvalues as well as the I/O configura-tion and application specificparameters like acceleration anddeceleration times. After this, theACS800 is ready for your process.

All this saves your time enablingyou to concentrate on essentialissues.

On-line info systemTo make it easier and more infor-mative, there is an on-line infosystem available at each stephelping to set the correct values foreach parameter. Just one push ofthe button and useful hints andinformation for that specific stageare available to you.

Each step also includes reference tothe printed manuals if even morespecific information is needed.

Features• Easy and fast commissioning

procedure• Intelligent guide to assist you

through the commissioning• Your own language• On-line info system always

available

The ACS800 offers you all this as astandard feature.

20 3AFE 64572504 REV E EN 17.10.2003

Adaptive ProgrammingNo extra hardware or software needed.

The freely programmable I/O andthe extensive parameter selectionsmake the ACS800 highly suitable assuch for most applications. TheACS800, however, goes one stepfurther with the addition of AdaptiveProgramming as a standard feature.It is like having a small PLC insideyour drive. Adaptive Programmingneeds no additional hardware orsoftware but is always there whenneeded.

Programming done in a fewminutesAdaptive Programming consists of aset of blocks, which can be pro-grammed to perform any of thepredefined set of functions. All thecommon functions for making a realblock program are available to you.

The user can freely define inputs tothe blocks, wiring between theblocks and connections to the driveI/O or to the drive control. In thisway the user is able to create newinput and/or output signals andmodify the drive’s speed or torquecontrol.

Programming the new ACS800 couldnot be any easier. All you need isthe control panel and the program-ming is as simple as settingparameters. With Adaptive Program-ming the user is really able to modifythe new ACS800 to suit the processperfectly.

Because no extra hardware orsoftware is needed, the program-ming can be done in a few minuteseven on-site.

Optimal adaptability• Small PLC inside• Program your drive on-site during

commissioning• Create your own I/O signals,

modify speed or torque referencechain or set a timer

• Do it without any additionalhardware or software

• As simple as setting a parameter

There is also a PC tool available forAdaptive Programming.

Features• 15 programmable function blocks• Available functions:

• Logical: AND, OR and XOR• Mathematical: add, mul, div,

abs, max and min• Other: timer, switch, comparator,

filter, SR, PI and user defined warnings or faults

• Freely definable execution order• Easy documentation

The ACS800 offers you all this as astandard feature!

213AFE 64572504 REV E EN 17.10.2003

Control SolutionsABB’s ready-made Control Solutions for specific drive applications.

Centrifuge ControlPractical programmable sequencesfor conventional centrifuges. De-canter Control for accurate speeddifference control of two shafts.

Extruder ControlHigh starting torque, accuratespeed/torque control and overloadprotection for demanding extruderapplications.

Pump and Fan ControlPump and Fan Control providesbetter flow control and cost sav-ings up to 5 parallel motors invarious industrial pump and fanapplications.

Spinning Control & TraverseControlSpinning Control and TraverseControl make a perfect pair forprecise control of spinning andtraverse drives in textile machines.

Crane Drive ControlThe cost effective crane drive withoptimal operational safety andoutstanding performance alreadybuilt in.

Master/Follower ControlReliable control via fibre optic linkof several drives when motor shaftsare coupled together.

The main advantages ofABB’s control solutions:• Application-dedicated features• Improved production• No external PLC• User-friendly• Easy to use• Energy savings• Smooth power loss ridethrough• Reduced costs• Adaptive protections

22 3AFE 64572504 REV E EN 17.10.2003

Control SolutionsCentrifuge Control.

Centrifuge &Decanter Centrifuge as oneThe Centrifuge application consistsof programmable sequences forcentrifuges e.g. in the food andbeverage industries. The DecanterControl is integrated with theCentrifuge Control. This feature canbe applied in all applicationsneeding co-ordinated speed differ-ence control.

AC drives designed forextruder applicationsAn extruder is an application wherematerial typically in granulate orpulverized form is driven through ascrew to achieve a continuousmaterial form to be further modifiedin the manufacturing process. Dueto the material characteristics highstarting torque is often needed. Thescrew and also the delicate me-chanical parts of the machineryneed to be protected against over-load.

Control SolutionsExtruder Control.

Extruder applicationfeatures• High starting torque, excellent

speed accuracy without encoder• Adaptive torque limitation feature• Two sets of parameterised stall

protection functions• Digital potentiometer with two

different accelerating anddecelerating ramp times

• Four control locations

Centrifuge Control features• Centrifugation patterns• Common DC-link possibility

Additional Decanter Controlfeatures• Direct communication between

bowl and scroll drive throughoptical fibres

• Automatic scaling of processspeed based on the given gearbox and belt ratio

• Speed difference control• Load compensation of scroll

drive

A decanter (separator, centrifuge) isused to separate solid particles fromfluid. In a typical decanter tworotating shafts called bowl andscroll are used. Direct TorqueControl enables smooth operationwith different kinds of fluid viscosityand automatically adapts to loadchanges.

233AFE 64572504 REV E EN 17.10.2003

Control SolutionsPump and Fan Control.

IntroductionThere are many pump and faninstallations with quite extensiveflow variations. Such are water andsewage systems, air conditioning,district heating and different indus-trial applications. A commonsolution for these is to run severalfixed speed pumps or fans inparallel and flow control is made byswitching them on and off. This

Pumping station for two pumps. ACS800 is installed inside thealternation switchgear cabinet.

Mains 400 V/50 Hz Alternationswitchgearcabinet

Pressuretransducer

0...10 bar4...20 mA

M17.5 kW1450 rpm14.8 A

M27.5 kW1450 rpm14.8 A

Features• The maximum number of units

(pumps or fans) in parallel is 5(1 with speed control and 4 withfixed speed)

• PI controller with•setpoint adjustment internal or

external•actual value with five selectable

units• Setpoint steps for 4 motors• Sleep and wake up level and

delay settings• Start and low frequency settings

for 4 motors• Start and stop delays• Autochange delay and level

settings• Automatic interlocking between

motors

kind of control causes discontinu-ous flow and there is a risk ofdamage caused by pressure strokes.Better flow control can be achievedwith variable speed drives. The costcan be reduced by putting a vari-able speed drive to one unit onlyand controlling the fixed speedunits with the Pump and FanControl application, PFC.

24 3AFE 64572504 REV E EN 17.10.2003

Control SolutionsSpinning Control & Traverse Control.

ACS800 Spinning Control is asolution for the precise control ofspinning machine and for prevent-ing yarn breakages. The ACS800drive features allow maximumproduction and prevent yarnbreakages during start-up and anypower losses.

The Traverse Control is designed torun traverse drives guiding yarn intoa package in textile machines. Toavoid layering at the reversal pointsof the yarn guide an instantaneouschange, a P-jump, is made at speed.

Features for SpinningControl:• Wobbulation function• Shiftwise production calculation• Automatic doff (pattern) selection• 4 speed time patterns

Features for TraverseControl:• Wide selection for base speed

reference• Dynamic quick steps, real or

proportional steps

The principle of the Spinning Control.

The principle of the Traverse Control.

YarnBobbin

Motor

GearDo

ffSpeedTimePattern

ACS800Spinning Control

ACS800Traverse Control

ACS800 withStandard program

Gear

Motor

GearMotor

Yarn

Yarn guide

Yarn package

P-jumpfunction

253AFE 64572504 REV E EN 17.10.2003

Control SolutionsCrane Drive Control.

Standard ready-to-use crane drivesolution with optimal operationalsafety and outstanding crane driveperformance.

Crane Drive ControlThe cost-effective crane drive withsafety and performance alreadybuilt in.

• Easy installation and start-upreduces the total project costs

• Ready to use with provenmodular crane functionality

• Accurate and fast torque responseincreases the operationalproductivity

• Smooth crane operation reducesmaintenance and damage costs

• Available as single drive andmulti drive with dynamic andregenerative braking

Flexible user interface• Joystick interface, with step or

continuous speed reference• Pendant control, with built in

motor potentiometer• Radio control, with step or

continuous speed reference• Fieldbus communication, for

connection to PLC• Limit switches, to ensure the

crane works within a safeoperation area

Operational safety• Mechanical brake functions for

controlling and supervising thebrake

• Adjustable fast stop procedure incase of overload or slack ropeetc.

• Torque proving ensures that themotor has produced sufficienttorque when opening the brakes

• Speed monitoring ensures thatthe speed stays within givenlimits. Also zero speed detection

• Torque monitoring supervises thecorrelation between the speedordered and actual motor speed

Outstanding performance• Start and stop logic ensures that

torque is available before thebrake is released

• 4 different ramp times. Individualsettings for acceleration anddeceleration ramp times in bothdirections

• Torque memory presets torquewhen starting the hoist withsuspended load, used foravoiding load drops whenmechanical brake is released

• Power optimization ensuresmaximum hoist speed relative tothe load. This optimizes thecrane’s capacity

• Optical master-follower link,used for load sharing betweentwo mechanically connectedmotors. This can also be used forredundancy applications

• Electrical shaft function, forsynchronizing two drives withoutmechanical connection.Adjustable control for positioncorrection

26 3AFE 64572504 REV E EN 17.10.2003

ACS800 I/O

Standard I/O on RMIO-01 Board• 3 analog inputs: differential, common mode voltage,

galvanically isolated as a group.- One ±0(2)...10 V, resolution 12 bit- Two 0(4)...20 mA, resolution 12 bit

• 2 analog outputs:- 0(4)...20 mA, resolution 10 bit

• 7 digital inputs: galvanically isolated as a group(can be split in two groups)- Input voltage 24 V- Filtering (HW) time 1 ms

• 3 relay (digital) outputs:- Switchover contact- 24 V or 115/230 V AC- Max. 2 A

• Reference voltage output:- ±10 V ± 0.5%, max. 10 mA

• Auxiliary power output:- +24 V ± 10%, max. 250 mA

Optional I/OAnalog I/O Extension Module RAIO-01• 2 analog inputs: galvanically isolated from 24 V supply

and ground- ±0(2)...10 V, 0(4)... 20 mA or ±0...2 V, resolution 12 bits

• 2 analog outputs: galvanically isolated from 24 V supplyand ground- 0(4)...20 mA, resolution 12 bit

Digital I/O Extension Module RDIO-01• 3 digital inputs: individually galvanically isolated

- Signal level 24 to 250 V or 115/230 V AC• 2 relay (digital) outputs:

- Switchover contact- 24 V or 115/230 V AC- Max. 2 A

Pulse Encoder Interface Module RTAC-01• 1 incremental encoder input:

- Channels A, B and Z (zero pulse)- Signal level and power supply for the encoder is 24 or 15 V- Single ended or differential inputs- Maximum input frequency 200 kHz

Analog and digital I/O channels areused for different functions such ascontrol, monitoring and measurementpurposes (e.g. motor temperature).

Below are the standard control con-nections of the ACS800 single drivewith Factory Macro. For other ACS800application macros the functionsmay be different.

Reference voltage -10 VDC, 1 kohm < RL <

10 kohm

Reference voltage 10 VDC, 1 kohm< RL < 10 kohm

Speed reference 0(2) ... 10 V, Rin >200 kohm

By default, not in use. 0(4) ... 20 mA,Rin = 100 ohm

By default, not in use. 0(4) ... 20 mA,Rin = 100 ohm

Motor speed 0(4)...20 mA = 0...motornom. speed, RL < 700 ohm

Output current 0(4)...20 mA = 0...motornom. current, RL < 700 ohm

Stop/StartForward/Reverse

By default, not in use.

Acceleration & deceleration select

Constant speed selectConstant speed select

+24 V DC max. 100 mA

Digital groundDigital ground

Start interlock (0 = stop)

Auxiliary voltage output, non-isolated,24 V DC 250 mA

Relay output 1: ready

Relay output 2: running

Relay output 3: fault (-1)

^

^

VREF-

AGND

VREF+

AGND

AI1+

AI1-

AI2+

AI2-

AI3+

AI3-

AO1+

AO1-

AO2+

AO2-

DI1

DI2

DI3

DI4

DI5

DI6

+24VD

+24VD

DGND1

DGND2

DIIL

+24V

GND

RO11

RO12

RO13

RO21

RO22

RO23

RO31

RO32

RO33

X20

1

2

X21

1

2

3

4

5

6

7

8

9

10

11

12

X22

1

2

3

4

5

6

7

8

9

10

11

X23

1

2

X25

1

2

3

X26

1

2

3

X27

1

2

3

A

rpm

In addition, optional I/O extensionmodules are available providingadditional analog or digital connec-tions.

273AFE 64572504 REV E EN 17.10.2003

Control PanelACS800 with user-friendly functionality.

Start-up AssistantEasy commissioning withthe Start-up Assistant.The Start-up Assistantactively guides you throughthe commissioning proce-dure.

Parameter copyingParameter copy featureallows all drive parametersto be copied from onefrequency converter toanother to simplifycommissioning.

CentralisedcontrolOne panel cancontrol up to 31drives.

SimplearrangementParameters areorganised intogroups for easyprogramming.

Adaptive ProgrammingNo extra hardware orsoftware required forAdaptive Programming.

The ACS800 control panel providesa great deal of information in plain,easy-to-understand language.

Actual valueThe ACS800 control panel candisplay three separate actual valuessimultaneously.Examples of these are:

• Motor speed• Frequency• Current• Torque• Power• References• DC bus voltage• Output voltage• Heatsink temperature• Operating hours• Kilowatt hours

Control PanelMultilingual alphanumeric display(4 lines x 20 characters) – plain textmessages in 14 languages.

Intelligent removable control panelcan be mounted on the ACS800enclosure or remotely.

Local drive operation from controlpanel, including LOCAL/REMOTEselection, START/STOP, RESET,MOTOR ROTATION DIRECTIONand REFERENCE setting.

Fault memoryA built-in fault memorystores information relatingto the latest 64 faults, eachwith a time stamp.

28 3AFE 64572504 REV E EN 17.10.2003

Fieldbus ControlGateway to your process.

ABB AC drives have the connectiv-ity to major automation systems.This is achieved with a dedicatedgateway concept between thefieldbus systems and ABB drives.

The fieldbus gateway is a snap-onmodule that can be easily mountedinside the drive. As a result of thewide range of fieldbus gateways,your choice for an automationsystem becomes independent ofyour decision to use first-class ABBAC drives.

Manufacturing FlexibilityDrive controlThe drive Control Word (16 bit)provides a wide variety of functionsfrom Start, Stop and Reset to RampGenerator control. Typical setpointvalues like Speed, Torque andPosition can be transmitted to thedrive with 15 bit accuracy.

Drive monitoringA set of drive parameters and/oractual signals, like torque, speed,position, current etc., can be se-lected for cyclic data transferproviding fast data for operatorsand the manufacturing process.

Reduced Installation andEngineering EffortCablingSubstituting the large amount ofconventional Drive Control cablingwith a single twisted pair reducescosts and increases system reliability.

DesignThe use of Fieldbus Control reducesengineering time at installation dueto the modular structure of thehardware and software.

Commissioning and assemblyThe modular machine configurationallows pre-commissioning of singlemachine sections and provides easyand fast assembly of the completeinstallation.

Drive diagnosticsAccurate and reliable diagnosticinformation can be obtained via thedrive Alarm, Limit and Fault Wordsreducing the down time of the driveand therefore also the down time ofthe manufacturing process.

Drive parameter handlingTotal integration of the drives in theproduction process is achieved bysingle parameter read/write up tocomplete parameter set-up ordownload.

Easy to expandSerial communication simplifies thelatest trend of modular machinedesign enabling expansion of theinstallation at a later stage with loweffort.

Currently Available Gateways• PROFIBUS-DP• DeviceNet• CANopen• ControlNet• ModbusPlus• LONWORKS®

• Modbus• Ethernet• InterBus-S

293AFE 64572504 REV E EN 17.10.2003

Dynamic BrakingBrake Choppers and Resistors.

Brake ChopperThe ACS800 series has in-builtbrake choppers for all types.Therefore, no additional space orinstallation time is needed. Thebrake chopper is part of the stan-dard delivery for the R2 and R3frames. For the other frames abrake chopper is a selectableoption.

Braking control is integrated intothe ACS800 series. It controls thebraking, supervises the system status

and detects failures such as brakeresistor and resistor cable shortcircuits, chopper short circuit, andcalculated resistor overtemperature.

Brake ResistorThe SACE/SAFUR brake resistorsare separately available for allACS800 types. Resistors other thanthe standard resistors may be usedproviding the specified resistancevalue is not decreased, and the heatdissipation capacity of the resistor issufficient for the drive application.

For ACS800 units, no separate fusesin the brake circuit are required ifthe following conditions are met:• The ACS800 mains cable is

protected with fuses• No mains cable/fuse overrating

takes place

ACS800 type Brake Chopper Brake Resistor(s)Power

Continuous Type R E r Prcont

Pbrcont [kW] [Ohm] [kJ] [kW]

ACS800-01-0001-2 0.6 SACE08RE44 44 248 1ACS800-01-0002-2 0.8 SACE08RE44 44 248 1ACS800-01-0003-2 1.1 SACE08RE44 44 248 1ACS800-01-0004-2 1.5 SACE08RE44 44 248 1ACS800-01-0005-2 2.2 SACE15RE22 22 496 2ACS800-01-0006-2 3 SACE15RE22 22 496 2ACS800-01-0009-2 4 SACE15RE22 22 496 2ACS800-01-0011-2 5.5 SACE15RE13 13 496 2ACS800-01-0016-2 11 SAFUR90F575 8 1800 4.5ACS800-01-0020-2 17 SAFUR90F575 8 1800 4.5ACS800-01-0025-2 23 SAFUR80F500 6 2400 6ACS800-01-0030-2 28 SAFUR125F500 4 3600 9ACS800-01-0040-2 33 SAFUR125F500 4 3600 9ACS800-01-0050-2 45 2 x SAFUR125F500 2 7200 18ACS800-01-0060-2 56 2 x SAFUR125F500 2 7200 18ACS800-01-0070-2 68 2 x SAFUR125F500 2 7200 18

UN = 230 V (208, 220, 230, 240 V)ACS800 type Brake Chopper Power Brake Resistor(s)

5 / 60 s 10 / 60 s 30/60 s Continuous Type R E r Prcont

Pbr5 [kW] Pbr10 [kW] Pbr30 [kW] Pbrcont [kW] [Ohm] [kJ] [kW]

ACS800-02/04-0080-2 68 68 68 54 SAFUR 160F380 1.78 3600 9ACS800-02/04-0100-2 83 83 83 54 SAFUR 160F380 1.78 3600 9ACS800-02/04-0120-2 105 67 60 40 2xSAFUR200F500 1.35 10800 27ACS800-02/04-0140-2 135 135 135 84 2xSAFUR160F380 0.89 7200 18ACS800-02/04-0170-2 135 135 135 84 2xSAFUR160F380 0.89 7200 18ACS800-02/04-0210-2 165 165 165 98 2xSAFUR160F380 0.89 7200 18ACS800-02/04-0230-2 165 165 165 113 2xSAFUR160F380 0.89 7200 18ACS800-02/04-0260-2 223 170 125 64 4xSAFUR160F380 0.45 14400 36ACS800-02/04-0300-2 223 170 125 64 4xSAFUR160F380 0.45 14400 36




ACS800-01-0003-3 1.1 SACE08RE44 44 248 1ACS800-01-0004-3 1.5 SACE08RE44 44 248 1ACS800-01-0005-3 2.2 SACE08RE44 44 248 1ACS800-01-0006-3 3 SACE08RE44 44 248 1ACS800-01-0009-3 4 SACE08RE44 44 248 1ACS800-01-0011-3 5.5 SACE15RE22 22 496 2ACS800-01-0016-3 7.5 SACE15RE22 22 496 2ACS800-01-0020-3 11 SACE15RE22 22 496 2ACS800-01-0025-3 23 SACE15RE13 13 496 2ACS800-01-0030-3 28 SACE15RE13 13 496 2ACS800-01-0040-3 33 SAFUR90F575 8 1800 4.5ACS800-01-0050-3 45 SAFUR90F575 8 1800 4.5ACS800-01-0060-3 56 SAFUR90F575 8 1800 4.5ACS800-01/07-0070-3 68 SAFUR80F500 6 2400 6ACS800-01/07-0100-3 83 SAFUR125F500 4 3600 9ACS800-01/07-0120-3 113 SAFUR125F500 4 3600 9

ACS800 type Brake Chopper Power Brake Resistor(s)



ACS800-02/04/07-0140-3 135 135 100 80 SAFUR200F500 2.70 5400 13.5ACS800-02/04/07-0170-3 165 150 100 80 SAFUR200F500 2.70 5400 13.5ACS800-02/04/07-0210-3 165 150 100 80 SAFUR200F500 2.70 5400 13.5ACS800-02/04/07-0260-3 240 240 240 173 2XSAFUR210F575 1.70 8400 21ACS800-02/04/07-0320-3 300 300 300 143 2xSAFUR200F500 1.35 10800 27ACS800-02/04/07-0400-3 375 375 273 130 4xSAFUR125F500 1.00 14400 36ACS800-02/04/07-0440-3 473 355 237 120 4xSAFUR210F575 0.85 16800 42ACS800-02/04/07-0490-3 500 355 237 120 4xSAFUR210F575 0.85 16800 42

UN = 400 V (380, 400, 415 V)

30 3AFE 64572504 REV E EN 17.10.2003

UN = 500 V (380, 400, 415, 440, 460, 480 and 500 V)

UN = 690 V (525, 575, 600, 660 and 690 V)

Maximum braking power of the ACS800 equippedwith the standard chopper and the standard resistor.P br5 = 5 s/ 1 min.P br10 = 10 s/ 1 min.P br30 = 30 s/ 1 min.

The drive and the chopper will withstand thisbraking power for 5/10/30 seconds every oneminute. Note: The braking energy transmittedto the resistor during any period shorter than400 seconds may not exceed Er . (Er variesdepending on the resistor).

Pbrcont= Continuous brake chopper power. The valueapplies to the minimum resistance value. With ahigher resistance value the Pbrcont may increasein some ACS800-02/04/07 units.

R = Resistance value for the listed resistor type.Note: This is also the minimum allowableresistance value for the brake resistor.

Er = Energy pulse that the resistor assembly willwithstand (400 s duty cycle). This energy willheat the resistor element from 40°C to themaximum allowable temperature.

Prcont = Continuous power (heat) dissipation of theresistor when placed correctly. Energy Er

dissipates in 400 seconds.




ACS800-01-0004-5 1.5 SACE08RE44 44 248 1ACS800-01-0005-5 2.2 SACE08RE44 44 248 1ACS800-01-0006-5 3 SACE08RE44 44 248 1ACS800-01-0009-5 4 SACE08RE44 44 248 1ACS800-01-0011-5 5.5 SACE08RE44 44 248 1ACS800-01-0016-5 7.5 SACE15RE22 22 496 2ACS800-01-0020-5 11 SACE15RE22 22 496 2ACS800-01-0025-5 15 SACE15RE22 22 496 2ACS800-01-0030-5 28 SACE15RE13 13 496 2ACS800-01-0040-5 33 SACE15RE13 13 496 2ACS800-01-0050-5 45 SAFUR90F575 8 1800 4.5ACS800-01-0060-5 56 SAFUR90F575 8 1800 4.5ACS800-01-0070-5 68 SAFUR90F575 8 1800 4.5ACS800-01/07-0100-5 83 SAFUR125F500 4 3600 9ACS800-01/07-0120-5 113 SAFUR125F500 4 3600 9ACS800-01/07-0140-5 135 SAFUR125F500 4 3600 9




ACS800-02/04/07-0170-5 165 132 2) 120 80 SAFUR200F500 2.70 5400 13.5ACS800-02/04/07-0210-5 198 132 2) 120 80 SAFUR200F500 2.70 5400 13.5ACS800-02/04/07-0260-5 198 1) 132 2) 120 80 SAFUR200F500 2.70 5400 13.5ACS800-02/04/07-0320-5 300 300 300 300 2xSAFUR125F500 2.00 7200 18ACS800-02/04/07-0400-5 375 375 375 234 2XSAFUR210F575 1.70 8400 21ACS800-02/04/07-0440-5 473 473 450 195 2xSAFUR200F500 1.35 10800 27ACS800-02/04/07-0490-5 480 480 470 210 2xSAFUR200F500 1.35 10800 27ACS800-02/04/07-0550-5 600 400 4) 300 170 4xSAFUR125F500 1.00 14400 36ACS800-02/04/07-0610-5 600 3) 400 4) 300 170 4xSAFUR125F500 1.00 14400 36




ACS800-01-0011-7 5.5 SACE08RE44 44 248 1ACS800-01-0016-7 7.5 SACE08RE44 44 248 1ACS800-01-0020-7 11 SACE08RE44 44 248 1ACS800-01-0025-7 15 SACE15RE22 22 496 2ACS800-01-0030-7 18.5 SACE15RE13 13 496 2ACS800-01-0040-7 22 SACE15RE13 13 496 2ACS800-01-0050-7 30 SACE15RE13 13 496 2ACS800-01-0060-7 37 SACE15RE13 13 496 2ACS800-01/07-0070-7 45 SAFUR90F575 8 1800 4.5ACS800-01/07-0100-7 55 SAFUR90F575 8 1800 4.5ACS800-01/07-0120-7 75 SAFUR90F575 8 1800 4.5




ACS800-04/07-0140-7 125 5) 110 90 75 SAFUR80F500 6.00 2400 6ACS800-04/07-0170-7 125 6) 110 90 75 SAFUR80F500 6.00 2400 6ACS800-04/07-0210-7 125 6) 110 90 75 SAFUR80F500 6.00 2400 6ACS800-04/07-0260-7 135 7) 120 100 80 SAFUR80F500 6.00 2400 6ACS800-04/07-0320-7 300 300 300 260 SAFUR200F500 2.70 5400 13.5ACS800-04/07-0400-7 375 375 375 375 SAFUR200F500 2.70 5400 13.5ACS800-04/07-0440-7 430 430 430 385 SAFUR200F500 2.70 5400 13.5ACS800-04/07-0490-7 550 400 315 225 2xSAFUR125F500 2.00 7200 18ACS800-04/07-0550-7 550 400 315 225 2xSAFUR125F500 2.00 7200 18ACS800-04/07-0610-7 550 400 315 225 2xSAFUR125F500 2.00 7200 18

1) 240 kW possible if Ambient below 33°C







All brake resistors are to be installed outside theconverter module.The SACE brake resistors are built in an IP 21 metalhousing.The SAFUR brake resistors are built in an IP 00 metalframe.

Brake Resistor Height Width Depth Weightmm mm mm kg

SACE08RE44 365 290 131 6.1SACE15RE22 365 290 131 6.1SACE15RE13 365 290 131 6.8SAFUR80F500 600 300 345 14SAFUR90F575 600 300 345 12SAFUR180F460 1320 300 345 32SAFUR125F500 1320 300 345 25SAFUR200F500 1320 300 345 30SAFUR210F575 1320 300 345 27

313AFE 64572504 REV E EN 17.10.2003

Output filtersFactory installed and external filters.

As with all frequency convertersemploying the most modern IGBTinverter technology, the ACS800output comprises - regardless ofoutput frequency - pulses of ap-proximately 1.35 times the mainsnetwork voltage with a very shortrise time. The voltage can be almostdouble at the motor terminals,depending on motor cable proper-ties.

Du/dt filtering suppresses inverteroutput voltage spikes and rapidvoltage changes that stress motorinsulation. Additionally, du/dtfiltering reduces capacitive leakagecurrents and high frequency emis-sion of the motor cable as well ashigh frequency losses and bearingcurrents in the motor.

When to Use? The need of du/dtfiltering depends on the motorinsulation. For information on the

Motor type Nominal mains Motor insulation requirementvoltage (UN)

ABB M2 and UN ≤ 500 V Standard insulation system.M3 motors 500 V < UN ≤ 600 V Standard insulation system in conjunction with du/dt filtering or reinforced insulation.

600 V < UN ≤ 690 V Reinforced insulation system in conjunction with du/dt filtering.ABB form-wound 380 V < UN ≤ 690 V Standard insulation system.HXR and AM motorsABB random-wound 380 V < UN ≤ 690 V Check motor insulation system with the motor manufacturer.HXR and AM motors du/dt filtering with voltages over 500 V.Non-ABB UN ≤ 420 V Insulation system must withstand ÛLL=1300 V.Random-wound 420 V < UN ≤ 500 V If the insulation system withstands ÛLL=1600 V and ∆t=0.2 µs, du/dt filtering is

not required. With du/dt filtering, the insulation system must withstand ÛLL=1300 V.500 V < UN ≤ 600 V If the insulation system withstands ÛLL=1800 V, du/dt filtering is not required.

With du/dt filtering, the insulation system must withstand ÛLL=1600 V.600 V < UN ≤ 690 V If the motor insulation system withstands ÛLL=1800 V, du/dt filtering is not required.

Non-ABB Form-wound 600 V < UN ≤ 690 V If the motor insulation system withstands ÛLL=2000 V and ∆t=0.3 µs,du/dt filtering is not required.

construction of the motor insula-tion, consult its manufacturer. If themotor does not fulfil the followingrequirements, the lifetime of themotor might shorten.

Additionally insulated N-end (non-driven end) bearings and / orcommon mode filters are requiredto motor bearing currents withmotors bigger than 100 kW. Formore information see ACS800hardware manuals.

SymbolUN

Û LL

∆t

ExplanationNominal mains voltage.Peak line to line voltage at motor terminals.Rise time, i.e. interval during which line to line voltage at motor terminals changes from 10% to 90% of fullvoltage range.

Filter selection table for ACS800

32 3AFE 64572504 REV E EN 17.10.2003

Dimensions and Weights of thedu/dt filters

ApplicabilityFactory-installed du/dt filters areavailable for ACS800-07/-17. Theyare installed inside the convertercubicle. The filters are also sepa-rately available for other ACS800types.

Then they need to be mountedexternally. Unprotected (IP 00)filters must be encased.

du/dt filter type (3 filters included in kits marked *)

ACS800

Heightmm

Widthmm

Depthmm

Weightkg

du/dt filter

** 3 filters included, dimensions apply for one filter.

Protectedto IP 22

Protectedto IP 54

Unprotected (IP 00)

NOCH0016-60 195 140 115 2.4

NOCH0016-62/65 323 199 154 6

NOCH0030-60 215 165 130 4.7

NOCH0030-62/65 348 249 172 9

NOCH0070-60 261 180 150 9.5

NOCH0070-62/65 433 279 202 15.5

NOCH0120-60** 200 154 106 7

NOCH0120-62/65 765 308 256 45

AOCH0260-70** 190 340 242 15.9

AOCH0400-70** 190 340 257 20.7

External du/dt filters for ACS800-01 and ACS800-04

400 V 500 V 690 V-0003-3-0004-3 -0004-5-0005-3 -0005-5-0006-3 -0006-5 1 1 1-0009-3 -0009-5-0011-3 -0011-5 -0011-7

-0016-5-0016-3 -0020-5 -0016-7-0020-3 -0020-7 1 1 1

-0025-7-0025-3 -0025-5 -0030-7-0030-3 -0030-5 -0040-7-0040-3 -0040-5 -0050-7 1 1 1-0050-3 -0050-5 -0060-7

-0060-5-0060-3 -0070-5 -0070-7-0070-3 -0100-5 -0100-7 1 1 1

-0120-7-0100-3 -0120-5 1-0120-3 -0140-5 1-0140-3 -0170-5 -0140-7 1-0170-3 -0210-5 -0170-7-0210-3 -0260-5 -0210-7 1-0260-3 -0320-5 -0260-7-0320-3 -0400-5 -0320-7 2

-0400-7-0400-3 -0440-5 -0440-7-0440-3 -0490-5 -0490-7 2-0490-3 -0550-5 -0550-7

-0610-5 -0610-7

NO

CH

0016

-60

NO

CH

0030

-60

NO

CH

0070

-60

*NO

CH

0120

-60

*NO

CH

0260

-60

*AO

CH

0260

-70

*AO

CH

0400

-70

NO

CH

0016

-62

NO

CH

0030

-62

NO

CH

0070

-62

NO

CH

0120

-62

NO

CH

0016

-65

NO

CH

0030

-65

NO

CH

0070

-65

NO

CH

0120

-65

333AFE 64572504 REV E EN 17.10.2003

Programming ToolDriveAP for Adaptive Programming.

Easy to use PC toolDriveAP is a PC tool to create,document, edit and downloadAdaptive Programs. AdaptiveProgramming can be done with thestandard control panel or withDriveAP. DriveAP offers a clear andeasy way to develop, test anddocument Adaptive Programs witha PC.

DriveAP is a user-friendly tool tomodify function blocks and theirconnections. No special program-ming skills are required. Basicknowledge about block program-ming is enough.

Adaptive Programming results areeasy to document as hard copies orstore as PC files with DriveAP.

Upload or downloadAdaptive Programs can be uploadedfrom connected drives and displayedgraphically on a PC screen e.g. forservice or documentation purposes.

Ready made Adaptive Programs canbe downloaded to any of theconnected drives.

Three operating modes• Stand Alone Mode - DriveAP

is not connected to a drive.Adaptive Programming can becarried out e.g. in the office anddownloaded later on

• Off-Line Mode - DriveAP isconnected to a drive. AdaptiveProgramming is carried out inbatch mode

• On-Line Mode - DriveAP isconnected to a drive. Changesto the program are writtenimmediately to the drive andactual values are shown on thescreen in real time

DriveAP is part of the DriveIT folderof the IndustrialIT.

Features• Easy to use tool, no special skills

required• Create and download new

programs• Document your programs• Upload existing programs from

the drive• Operating modes

• Stand Alone• Off-Line• On-Line

34 3AFE 64572504 REV E EN 17.10.2003

Integration ToolDriveOPC for Windows™ based monitoring.

DriveOPCDriveOPC is a software packagewhich allows OLE for ProcessControl (OPC) communicationbetween Windows applications andABB drives. It is an ideal tool forintegrating commercial PC monitor-ing software and ABB drives.

DriveOPC can access all drivesconnected to the fast optical linkof the drives. The number ofmeasuring points is unlimited.

OPC based softwareOPC stands for Ole for ProcessControl, an open architectureinterface design defined by theinternational OPC Task Force. It isan open interface for FactoryAutomation.

Remote monitoringDriveOPC enables remote connec-tion over LAN (local areanetworks). The remote PC can beconnected by its IP address (e.g."164.12.43.33") or by the DNS name(e.g. "Gitas213").

Read access to:• Drive status: local, running,

direction, fault, warning, homing,reference

• Signals and parameters• Fault logger contents• Event logger contents• General drive information• Data logger settings, status and

contents

Write access to:• Drive Control: local, start, stop,

forward, reverse, coast stop, resetfault, home, teach-in, contactor-on/off, reference

• Parameters• Fault logger clear• Data logger init, start, trig, clear

DriveOPC is part of the DriveIT

folder of the IndustrialIT.

Features:• To control and monitor with PC-

based process control software• Standard interface• Remote connection over LAN

(local area networks)• Access to

• Drive control• Signals and parameters• Data and Fault loggers

353AFE 64572504 REV E EN 17.10.2003

Quality dimensioningDriveSize is a PC program forhelping the user to select an opti-mal motor, frequency converter andtransformer, especially in thosecases where a straightforwardselection from a catalogue is notpossible. Additionally it can be usedto compute currents, networkharmonics and to create documentsabout the dimensioning based onactual load. DriveSize contains acurrent version of ABB motor andfrequency converter catalogues.The default values make DriveSizesimple to use, but the user is pro-vided with ample options for driveselection. The shortcut keys makedrive selection easy while stillhonouring the relatively compli-cated rules. A manual selectionmode is also supported.DriveSize is currently used by morethan 1000 engineers globally.

Engineering ToolDriveSize for dimensioning motors and drives.

DriveSize is for drive systemcomponents• 3-phase standard, customized,

Ex and user defined motors• ABB low voltage AC drives

ACS400ACS600ACS800

• Transformers

DriveSize functionsThe software performs dimension-ing based on the following input:• Speed range and mechanical load

with overloads• Ambient temperature and

altitude• Required IP-class and allowed

temperature rise• Supply network characteristics• Load type and duty cycle• Optionally current requirements

for inverters• DC power requirement for line

supply unit• Apparent power requirement for

the transformer

Additional functionsThe software also enables you to:• Calculate the network harmonics

of individual drive or set ofdrives

• Obtain efficiency values• See your selections in graphical

or numeric form• Select manually unit from the

database• Print out reports• Save the dimensioning results

into files

Benefits• Select an optimal motor,

frequency converter andtransformer

• Dimensioning based on actualshaft load

• Documents dimensioningresults, graphical and numericalpresentation

• Network harmonic and powerfactor calculaton

• Print out and save the results

36 3AFE 64572504 REV E EN 17.10.2003

Start-up and Maintenance ToolDriveWindow 2

Powerful and versatile• DriveWindow can access all

drives connected to the highspeed fiber optic network

• Signal values can be viewed asgraphs from the drive/drives

• A screenful of signals andparameters from the drive can bemonitored and edited at one time(off-line or on-line)

• View data collected and stored inthe drive

• Fault diagnosis; DriveWindowindicates the status of drives, andalso reads fault history data fromthe drive

• Remote monitoring, plant widemonitoring with two PCs

• Back-up of drive parameters; infault situations the file can beeasily reloaded, resulting in timesavings

• Back-up parameters or softwarefrom the drive into PC files. Thisversion allows the entire controlboard content to be saved andrestored later - even to emptycontrol boards. One empty sparecontrol card can function as aspare part for many differentsizes of drives

DriveWindow is part of the DriveIT

folder of the IndustrialIT.

WindowsTM -based, user-friendlyABB's DriveWindow is an ad-vanced, easy-to-use tool for thecommissioning and maintenance ofdrive systems in different industries.Its host of features and clear,graphical presentation of the opera-tion make it a valuable addition toyour system providing informationnecessary for troubleshooting,maintenance and service, as wellas training.

DriveWindow is fully 32 bit andruns in the newer Microsoft® Windowsenvironments. DriveWindow hasconnection kits for both laptop anddesktop PCs.

With DriveWindow the user is ableto follow the co-operation of twoor more drives simultaneously bycollecting the actual values fromthe drives onto a single screen orprintout.

Additionally, the client part ofDriveWindow may reside on oneLocal Area Network PC, and theserver side on another PC closer tothe drives. This enables plant-widemonitoring to be easily accom-plished with two PCs.

Features• Easy-to-use tool for

commissioning and maintenance• Several drives connected and

monitored at the same time• Monitor, edit or save signals and

parameters, clear graphicalpresentation

• High speed communicationbetween PC and drive

• Versatile back-up functions

373AFE 64572504 REV E EN 17.10.2003

Simple to useThe DriveWindow Light 2.1 is acomprehensive commissioning andmaintenance tool for ABB drives.This easy-to-use software is forediting, uploading and download-ing drive parameters and, forexample, monitoring the actualvalues and status information ofthe drive system.

DriveWindow Light 2.1 enables mostdrive parameters to be set offline inthe office when uploaded from thedrive, and then saved in the drive-specific files. The files can be furthermodified and downloaded to therespective drives at the installationsite.

Start-up and Maintenance ToolDriveWindow Light 2.1

The configuration can then be testedand fine-tuned using the software'smonitoring feature. The final param-eter settings can be saved forback-up purposes and also printedout easily for customer documenta-tion.

The DriveWindow Light 2.1 packageconsists of the software tool, basedon 32-bit architecture of Microsoft®

Windows environment, and the RS-232/RS-485 PC connection unit kithardware. DriveWindow Light canalso be used for the ACS140 andACS400 with RS-485/232 adapter.

DriveWindow Light is part of theDriveIT folder of the IndustrialIT.

Practical functions• Parameter browser for editing

(online/offline) and viewingparameter values online

• Parameter compare function forparameters in a drive and aparameter file

• Parameter back-up and restore• Easy adjustment of pointer type

parameters, e.g. AdaptiveProgramming

• Graphical and numericalmonitoring of signals

• Control panel with step function

38 3AFE 64572504 REV E EN 17.10.2003

Remote Monitoring ToolThe intelligent Ethernet module NETA-01.

Browser-based, user-friendlyThe intelligent Ethernet modulegives simple access to the drive viathe Internet communicating via astandard web browser. The usercan set up a virtual monitoringroom wherever there is a PC withan Internet connection or via asimple dial-up modem connection.This enables remote monitoring,configuration, diagnostics and,when needed, control. The drivecan also provide process relatedinformation, such as load level, runtime, energy consumption and I/Odata, the bearing temperature ofthe driven machine, for instance.

No PC needed at local endThe intelligent Ethernet module hasan embedded server with thenecessary software for the userinterface, communication and datastorage. This gives ease of access,real time information and thepossibility for two-way communica-tion with the drive, enablingimmediate response and actions,saving time and money. This ispossible without using a PC at thelocal end, as required by otherremote solutions.

E-mail alertsThe module can also send conditiontriggered event alerts to predefined

email addresses. This opens newpossibilities for the monitoring andmaintenance of unmanned applica-tions across a range of industries, forinstance water, wind power, buildingservices and oil & gas, as well asany decentralised application wherethe user needs access to the drivesfrom more than one location. It alsoprovides an opportunity for OEMsand system integrators to supporttheir installed base globally.

Powerful and versatileUp to nine drives can be connectedto the intelligent Ethernet module viafibre optic links. It is available as anoption for new drives, as well as anupgrade for existing systems.Ethernet allows the integration ofoffice and process environmentsinto a global network. The modulesupports the usual HTTP, IP, TCP,SMTP, BOOTP, UDP, Telnet and FTPprotocols, as well as Modbus/TCPbased process control. Access to themodule is secured by user ID andpasswords. Multiple security levelenables the allocation of differentaccess rights to normal users andadministrators. Even higher levelsof security can be achieved using aVirtual Private Network (VPN)connection.

The module is mounted onto astandard mounting rail inside oroutside the drive unit, dependingon drive type and configuration. Itconnects to the drive with fibreoptic cables. The size of the moduleis 93 (h) x 35 (w) x 76.5 (d) mm.

The IP address of the Ethernetmodule can be freely allocated. Theuser interface with the drive iscreated using embedded Javaapplets. The web page of themodule is opened like any otherweb address. The home pageshows a general overview of thesystem with traffic lights and actionbuttons to guide the user throughthe different sections.

Features• Virtual monitoring room for

• Monitoring• Configuration of parameters• Diagnostics• Control, if needed

• Browser based access via• Intra-/extra-/Internet or• Simple dial-up modem

connection• E-mail alerts to predefined

addresses• No PC needed at the local end• Can be used as a Modbus/TCP

bridge for control purposes

393AFE 64572504 REV E EN 17.10.2003

Energy saving with ACS800Environmental Product Declarations.

How much air pollution is causedby an electric motor or drive? Howdoes the manufacture and use ofelectric motors and drives affectwater quality? Or influence globalwarming? These were some of thequestions ABB asked itself when itdecided to assess and improve theenvironmental impact of its electricmotors and drives.

The solution was to provide Envi-ronmental Product Declarations(EPDs) for all core ABB products.EPDs describe the environmentalaspects and impacts of a productline over its entire life cycle.

The EPD program aims• To enable ABB designers to assess

and improve the environmentalperformance of a product over itsfull life cycle

• To facilitate a sound comparisonof the environmental performanceof alternative products, usingavailable environmental criteria

• To provide ABB’s customers withLCA data of ABB products tofacilitate environmentalassessments of their processes

• To promote the environmentalperformance of ABB products andservices among its stakeholdersand to enhance ABB’s business

The declarations are based on LifeCycle Assessment (LCA) studies andconform to ISO 14025.

ABB has published three EPDbrochures for the ACS800 for the18.5, 250 and 703 kW power ratings.

Reduce plant operatingcosts with the ACS800One of the most tangible benefits ofusing AC drives has always beenthe saving in energy-related operat-ing costs. AC drives save energy inmany cases, first and foremost in

flow control applications such aspumps, fans and compressors.Companies having installed ACdrives have already reaped hugesavings when mechanical controldevices such as throttling valves,dampers or hydraulic clutches havebeen replaced with electronic speedcontrol.

Even more energy savings areobtainable when older AC drivesare replaced by ABB AC drives. Theadditional energy saving can be 10%or even more. This is a result ofABB's uninterrupted product devel-opment focus on reducing losses indrive components and motors.

ABB’s unparalleled Direct TorqueControl (DTC) technology hasbecome a landmark in the drivesindustry thanks to its superior

control accuracy and frugality inpower usage.

The new industrial drive, theACS800, is equipped with DTCmotor control and exhibits top-class energy efficiency found in themarketplace today. It is a safeinvestment for a company whichvalues high performance, reliabilityand low operating costs.

Energy saving toolsThe software tools, PumpSave andFanSave, have been developed byABB for predicting the energysavings. They are available fordownload on the web at

www.abb.com/motors&drives ->AC drives -> Energy savingor email [email protected]

AC drive efficiency vs. time (75 kW)

AC drive efficiency

Motor efficiency inAC drive useTotal efficiency

Year - drive technology

Effi

cien

cy, %

3AFE 64572504 REV E EN 17.10.2003 Specifications subject to change without notice.The IndustrialIT wordmark and all above-mentioned product names in the form DriveIT are registered or pending trademarks of ABB.

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rivesP

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