En Acs800-607 HW C

ACS800
Hardware Manual
ACS800-607 3-phase Brake Units
List of related manuals
General manuals Code (English)
ACS800 Multidrive and Multidrive Modules Safety Instructions 3AFE64760432
ACS800 Multidrive Cabinet-installed Drives Mechanical Installation 3AFE68233402
ACS800 Multidrive and Multidrive Modules Planning the Electrical Installation 3AFE64783742
Drive hardware manuals and guides

ACS800-607 3-phase Brake Units Hardware Manual 3AFE68925916
ACS800-107 Cabinet-built Inverter Units (1.5 to 5430 kW) Hardware Manual 3AFE68233453
ACS800-207 Cabinet-installed IGBT Supply Units Hardware Manual 3AFE68233810
ACS800-307 (+V992) and ACS800-507 (+V992) cabinet-installed diode supply 3AUA0000069193
units (DSU) Hardware manual
ACS800-407 and ACS800-807 Cabinet-installed Thyristor Supply Units (TSU) 3AFE68243688
(639 to 5991 kW) User’s Manual
Drive firmware manuals and guides

ACS800 Brake Control Program Firmware Manual 3AFE68835631
ACS800 System Control Program 7.x Firmware Manual and 3AFE64670646
Adaptive Program Application Guide 3AFE68420075
ACS800 Standard Control Program 7.x Firmware Manual and 3AFE64527592
Adaptive Program Application Guide 3AFE64527274
ACS800 IGBT Supply Control Program 7.x Firmware Manual 3AFE68315735
ACS800 Diode Supply Control Program Firmware Manual 3AUA0000068937
ACS800 Crane Control Program Firmware Manual 3AFE68775230
ACS800 Master/Follower Application Guide 3AFE64590430
ACS800 Pump Control Application Program Firmware Manual 3AFE68478952
ACS800 Extruder Control Program Supplement 3AFE64648543
ACS800 Centrifuge Control Program Supplement 3AFE64667246
ACS800 Traverse Control Program Supplement 3AFE64618334
etc.
Option manuals and guides

ACS800-01/04/11/31/104/104LC Safe torque off function (+Q967), Application 3AUA0000063373
guide
Safety options for ACS800 cabinet-installed drives (+Q950, +Q951, +Q952, 3AUA0000026238
+Q963, +Q964, +Q967 and +Q968), Wiring, start-up and operation instructions
Manuals and quick guides for I/O extension modules, fieldbus adapters, etc.
You can find manuals and other product documents in PDF format on the Internet. See section Document library on the
Internet on the inside of the back cover. For manuals not available in the Document library, contact your local ABB
representative.
ACS800-607 3-phase Brake Units
Hardware Manual
3AFE68925916 Rev C
EN
EFFECTIVE: 2016-03-18
 2016 ABB Oy. All Rights Reserved.

5
Table of contents
Table of contents
About this manual

What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Target audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Related manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Essential information in other manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Abbreviations and terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Categorization by frame size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation and commissioning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Hardware description
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Operation basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Brake chopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Brake chopper control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Capacitor bank pre-charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Main circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Brake unit hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Layout drawing - bottom cable entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Layout drawing - top cable entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Brake module R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Brake module R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Power connections and control interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
RMIO board connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Type designation labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Type code of the brake unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Basic code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Option codes (plus codes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Type code of the brake module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Basic code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Option codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Planning the installation

Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Table of contents
6
Generic guidelines for the electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Thermal overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Protection in brake chopper failure and brake resistor overheat situations . . . . . . . . . . . . . . . . . . .28
Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
How the protection differs in TN and IT electrical power systems . . . . . . . . . . . . . . . . . . . . .28
Selecting the brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Placing the brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Installing the brake resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Selecting and routing the brake resistor cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Minimizing electromagnetic interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Maximum cable length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
EMC compliance of the complete installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Mechanical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Checking the insulation of the resistor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Connecting the resistor cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Connection diagram – three-conductor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Connection diagram – four-conductor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Wiring the fault indication from relay output RO1 to the main breaker . . . . . . . . . . . . . . . . . .36
Control cable connection procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Installation of optional modules and PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
PC connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Optional modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Cabling of fieldbus modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Fibre optic links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Start-up
Start-up checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Fault tracing
LEDs of the brake unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Maintenance
Reduced run capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Technical data
Table of contents
7
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Input and output voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Type equivalences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Dimensions, noise, losses and cooling air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Resistor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Resistor cable connection and lead-through data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Tightening torques for power connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Compliance with the Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
UL and CSA markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Example circuit diagrams

R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Dimensional drawings
R7i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
R8i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Bottom cable exit and entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Top cable exit and entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Product and service inquiries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Product training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Providing feedback on ABB Drives manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Document library on the Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Table of contents
8
Table of contents
9
About this manual
What this chapter contains

This chapter describes the intended audience and contents of the manual. It also
contains a flowchart of steps in checking the delivery, installing and commissioning
the brake unit. The flowchart refers to chapters/sections in this manual and other
manuals.
Compatibility
The manual is compatible with ACS800-607 cabinet-installed brake units based on
inverter modules.
Target audience
This manual is intended for people who plan the installation, install, commission, use
and service the brake units. Read the manual before working on the units. The
reader is expected to know the fundamentals of electricity, wiring, electrical
components and electrical schematic symbols.
Safety
Follow the safety instructions delivered with the drive.
• Read the complete safety instructions before you install, commission, or use
the brake unit. The complete safety instructions are given in ACS800 Multidrive
and Multidrive Modules Safety Instructions (3AFE64760432 [English]).
• Read the software function specific warnings and notes before changing the
default settings of the function. For each function, the warnings and notes are
given in the section describing the related user-adjustable parameters.
• read the task specific safety instructions before starting the task. See the
section describing the task.
WARNING! The main breaker of the drive must be opened in case relay output RO1
is de-energized. This is the only way to guarantee safe operation since in case of a
chopper failure the chopper is unable to disconnect the resistor from the
intermediate circuit. See page 20.
About this manual

10
Contents
Installation
Start-up
Fault tracing
Maintenance
Technical data
Dimensional drawings.
Related manuals
See the inside of the front cover.
Essential information in other manuals

For mechanical installation of the cabinet line up, see ACS800 Multidrive Mechanical
Installation (3AFE68233402 [English]).
For complete safety instructions, see ACS800 Multidrive and Multidrive Modules
Safety Instructions (3AFE64760432 [English]).
For planning the electrical installation, see ACS800 Multidrive and Multidrive
Modules Planning the Electrical Installation (3AFE64783742 [English]).
For external control interfaces, I/O connection diagram and fault tracing, see Brake
Control Program Firmware Manual (3AFE68835631 [English]).
About this manual

11
Abbreviations and terms

Abbreviation Explanation
AIMA I/O Module Adapter. Extension unit for the mounting of I/O extension modules,
such as RDIO, RAIO and RTAC.
APBU PPCS Branching Unit. Branches commands and information from the RMIO board
to parallel-connected brake modules. Likewise, the communication from the
parallel-connected brake modules is transmitted to the RMIO boards via the
branching unit.
DDCS Distributed Drives Communication System (a communication protocol used in
optical fibre communication inside and between ABB drives).
PPCS Power Plate Communication System (a communication protocol used in the
optical fibre link that controls the output semiconductors of a converter.
RDCO DDCS Communication Option Module. A satellite board that can be snapped on
the RMIO board to add the number of fibre optic channels available.
RDCU Drive Control Unit. The RMIO board is encapsulated in a casing called RDCU
Drive Control Unit. The unit is fastened with two screws onto a DIN rail leaving the
input and output terminals of the RMIO board accessible.
RMIO Motor Control and I/O Board. The board contains the Brake Control Program and
provides the control interfaces for the brake unit.
Term Explanation
Frame (size) Relates to the construction type of the brake unit.
To determine the frame size of a unit, refer to the rating tables in chapter Technical
data.
Inverter unit Converts the drive intermediate circuit DC current to AC current fed to the motor.
Categorization by frame size

Some instructions, technical data and dimensions and weights which concern only
certain frame sizes are marked with the symbol of the frame size (such as “2×R8i”).
The frame size is not marked on the brake unit designation label. To identify the
frame size of your unit, see the rating tables in chapter Technical data.
About this manual

12
Installation and commissioning flowchart
Task See
Select the cables and brake resistors. Selecting the brake resistors, page 28, Placing the brake
resistors, page 29 and Selecting and routing the brake
resistor cables, page 29
Plan the installation. ACS800 Multidrive and Multidrive Modules Planning the
Electrical Installation (3AFE64783742 [English])
Check the ambient conditions, ratings, required coolant Technical data

flow, resistor connections and other technical data.
Unpack and check the units. ACS800 Multidrive Mechanical Installation

(3AFE68233402 [English]).
Check that all necessary optional modules and equipment If the drive has been non-operational for more than one
are present and correct. year, the DC link capacitors need to be reformed. Ask ABB
Only intact units may be started up. for instructions.
Check the installation site and Install the unit mechanically. ACS800 Multidrive Mechanical Installation
Route the cables. ACS800 Multidrive and Multidrive Modules Planning the
Electrical Installation (3AFE64783742 [English]), Selecting
and routing the brake resistor cables, page 29
Check the insulation of the resistor circuit. Checking the insulation of the resistor circuit, page 32
Connect the resistor cables. Connect the control and the Installation, page 31
auxiliary control cables.
Check the installation. Start-up, page 41
Commission the drive and the brake unit. Start-up, page 41, Brake Control Program Firmware Manual
(3AFE68835631 [English])
About this manual

13

This chapter describes the operation and construction of ACS800-607 brake units.
Operation basics
Typically, the multidrive is equipped with a brake unit if:
• high capacity braking is needed and the drive cannot be equipped with a
regenerative supply unit
• a backup for the regenerative supply unit is needed.
The brake unit includes a brake chopper (brake module) or several parallel-
connected brake choppers. The brake chopper is actually a three-phase inverter
module (ACS800-104) that is connected and controlled in a particular way: The input
of the module is connected to the DC link of the drive directly and each output phase
connects to the DC link via a brake resistor.
Fuses
The brake unit is equipped with fuses as standard. The fuses protect the chopper
and the brake circuit cables in a cable short-circuit situation.
Brake chopper
The chopper connects the brake resistor to the intermediate circuit whenever the
voltage in the intermediate circuit (DC bus) exceeds the maximum limit which is
defined with a parameter setting in the Brake Control Program.
Energy consumption by the resistor losses lowers the voltage until the resistor can
be disconnected. The energy generated by the motor during a fast deceleration of
the drive typically causes the voltage to rise in the intermediate circuit.
Brake resistors
The brake resistors dissipate the surplus energy conducted by the choppers. The
brake units must be equipped with brake resistors by the user. The resistor types to
be used are specified in chapter Technical data.
Brake chopper control

The brake unit control board supervises system status and detects failures such as:
• brake resistor and resistor cable short-circuits
• chopper (IGBT) short-circuit
• control board failure
• chopper and resistor overtemperature.
14
For more information on the brake chopper control, operation, settings, diagnostics
and protections, see Brake Control Program Firmware Manual
Capacitor bank pre-charging

The DC capacitors of the brake and inverter modules are pre-charged by the supply
unit when it is started.
Main circuit diagram

DC+
DC link of the drive
DC–
DC+ and DC– fuses
ACS800-104 Brake module
Resistor fuses
U2 V2 W2
Quick connector of brake

module
Cabinet PE
ACS800-607
Resistor cabling (not

included in delivery)
Brake resistors (not

included in delivery)
15
Brake unit hardware
Layout drawing - bottom cable entry

The figure below shows a 500 mm wide cubicle with one R8i brake module. Bigger
units multiply this basic construction. If the unit consists of two R8i modules, there
are two similar cubicles side by side except that only one of them includes the
control electronics (control unit [RDCU] and branching unit [APBU]).
View from front, door closed View from front, door open
shrouds removed
No. Description
1 Control panel (option +J400) and LED

2 4
3 panel (option +J401)
1
2 DC– fuses
3 DC+ fuses
4 Resistor fuses
9
5 Brake module
6 Busbars for brake resistor cabling

(U2/V2/W2, behind the module)
5
(DC– side)
8 Brake module fan
9 Control unit (RDCU) 1)

6
7 10 Branching unit (APBU) (mounted on
10
the side wall) 1)
1)
8 There is only one RDCU and one APBU unit
per brake unit.
16
Layout drawing - top cable entry

The figure below shows a 700 mm wide cubicle with one R8i brake module. Bigger
units multiply this basic construction. If the unit consists of two R8i modules, there
are two similar cubicles side by side except that only one of them includes the
control electronics (control unit [RDCU] and branching unit [APBU]).
View from front, door closed View from front, door open
shrouds removed
No. Description
1 Control panel (option +J400) and LED

panel (option +J401)
2 3 2 DC– fuses
1 6 3 DC+ fuses
4 Brake module
5 Brake module fan

7
4 (U2/V2/W2)

8 (DC–)
8 Resistor fuses
9 Control unit (RDCU, mounted on the

side wall) 1)
9
10 Branching unit (APBU) 1)
1)
There is only one RDCU and one APBU unit
10 per brake unit.
5
17
Brake module R7i

Frames R7i and R8i inverter modules are also used as brake modules. When in
brake use, the modules are controlled by the Brake Control Program.
The frame R7i module has the DC input connection at the top, while the AC
connection is at the bottom. The DC voltage is connected to the input busbars
through fuses.
The drive control unit (type RDCU) containing the RMIO board is to be installed
separately.
The modules can be ordered with a 230 V (50 Hz) or 115 V AC (60 Hz) cooling fan
depending on the desired auxiliary voltage.
Front view with

cooling fan removed
1 Item Explanation
1 DC (input) connections.
2 Resistor (output) connection.

6
3 Cooling fan.
6 4 Power connection for cooling fan (X41).
5 Fibre optic connectors.
6 Prevention of unexpected start connector.
4
2
18
Brake module R8i

The modules run on wheels, which, along with the quick connector at the motor
output, enable quick replacement of a module for maintenance.
1
3
5
2
Item Explanation
1 DC (input) connections
2 Output busbars. These couple with the quick connector socket mounted in the cubicle
3 Fibre optic connectors of the AINT board. Connected to the RDCU drive control unit (via
an APBU branching unit in case of parallel modules)
4 Retractable support legs
5 Handle
6 Cooling fan
19
Power connections and control interfaces

The brake unit is controlled by an RDCU control unit which incorporates the RMIO
board. The RMIO board contains several analogue and digital I/O terminals as well
as three connection slots for other types of communication. The following diagram
shows the control interfaces, I/O options and power connections of a brake unit.
Control unit (RDCU)
Control panel. Motor control and

See the appropriate I/O board (RMIO)
Firmware Manual.
Communication module 1: fieldbus adapter (e.g.
Slot 1
RMBA, RDNA, RPBA) (all optional)
Slot 2
Communication module 3: DDCS adapter (RDCO-0x)

External control via analogue/ Slot 3 (optional)
digital inputs and outputs
PC, fieldbus AIMA

adapter Nxxx external I/O
interface
APBU Fibre optic link

branching unit 1)
Input power To motor
Supply Brake Brake Inverter

module(s) module(s) resistors module(s)
1) APBU is used only with parallel brake modules.
20
RMIO board connections

Default cable connections to the RMIO board are shown below.
X20
Terminal block size:
1 VREF- Reference voltage -10 V DC,
cables 0.3 to 3.3 mm2 (22 to 12 AWG) 2 GND 1 kohm < RL < 10 kohm
Tightening torque: X21
0.2 to 0.4 Nm (2 to 4 lbf in.) 1 VREF+ Reference voltage 10 V DC,
2 GND 1 kohm < RL < 10 kohm
3 AI1+ By default, not in use. 0(2)...10 V,
4 AI1- Rin > 200 kohm
5 AI2+ By default, not in use. 0(4)...20 mA,
6 AI2- Rin = 100 ohm
1)
Equip each resistor with an
overtemperature sensor of its own. Use 7 AI3+ By default, not in use. 0(4)...20 mA,
shielded twisted pair cable and ground 8 AI3- Rin = 100 ohm
the shield at the braking chopper end. 9 AO1+ By default, not in use. 0(4)...20 mA,
10 AO1- RL < 700 ohm
11 AO2+ By default, not in use. 0(4)...20 mA,
12 AO2- RL < 700 ohm
1) t° X22
t° t°
… 1 DI1 Resistor overtemperature detection 2)
2 DI2 By default, not in use
3 DI3 Not in use
4 DI4 Not in use
5 DI5 By default, not in use
6 DI6 Reset 2)
7 +24V +24 V DC max. 100 mA
2) non-programmable I/O 8 +24V
3)
Total maximum current shared between 9 DGND Digital ground
this output and optional modules installed 10 DGND Digital ground
on the board 11 DI7(DIIL) By default, not in use
X23
1 +24V Auxiliary voltage output and input, non-
2 GND isolated, 24 V DC 250 mA 3)
X25 Relay output 1
WARNING! The main breaker of the drive 1 RO11 Main breaker control 2)
must be opened in case relay output RO1 is 2 RO12 1 = no fault
de-energized. Wire the fault signal to the
3 RO13
main breaker control. See the next page for a
wiring principle and the circuit diagrams X26 Relay output 2
delivered with the drive for the actual wiring. 1 RO21 08.01 MAIN STATUS WORD bit 2
2 RO22 RDY TO BRAKE
3 RO23 1 = enabled
X27 Relay output 3
1 RO31 08.01 MAIN STATUS WORD bit 8
2 RO32 BRAKING
3 RO33 1 = braking
21
Type designation labels

The type designation label includes the ratings, valid markings, a type code and
a serial number. The brake module label is attached to the front panel of the module
and the label of the brake unit is attached to the inner side of the unit door. Example
labels are shown below .
No. Description
1. Serial number. The first digit of the serial number refers to the manufacturing plant. The next
four digits refer to the unit’s manufacturing year and week, respectively. The remaining digits
complete the serial number so that there are no two units or modules with the same number.
2. Type code. See sections Type code of the brake unit on page 22 and Type code of the brake
module on page 25.
3. Valid markings
4. Ratings of brake unit
5. Ratings of converter module when in inverter use
6. Ratings of converter module when in supply module use
7. Ratings of converter module when in brake use
Type designation label of ACS800-607 brake unit
4
3
2 1
Type designation label of ACS800-104 inverter, supply and brake module
5
6
2
3 1
22
Type code of the brake unit

The type code of the brake unit is indicated on the type designation label, attached
on the door of the brake unit (inside). The type code contains a summary of the
configuration of the brake unit. The first digits from left express the basic
configuration e.g. ACS800-607-1510-3.The optional selections are given thereafter,
separated by plus signs, e.g. +B055. The selections are described below.
Note: The information below is for quick reference only and does not contain all
conditions and details. For more information, contact the local ABB representatives.
Basic code
Digit Name/Description Alternatives
1…6 Product series ACS800
8…10 Product type 607 cabinet-installed brake unit
12…15 Size 0250…6500
17 Voltage rating 3 – Voltage range 380…415 V AC
5 – Voltage range 380…500 V AC
Option codes (plus codes)

This is a complete option code list for the brake units of ACS800 multidrive. Option
codes starting with the symbol zero (0) are selections that are not shown on the
nameplate (internal codes for the factory use). Default selections are marked by *.
Category Code Selection
Supply Frequency A012 Supply frequency 50 Hz *
Supply Frequency A013 Supply frequency 60 Hz
Degree of protection B052 IP21, UL type 1, NEMA 1 *
Degree of protection B053 IP22, UL type 1, NEMA 1
Degree of protection B054 IP42, UL type 1, NEMA 1
Degree of protection B055 IP54, UL type 12, NEMA12
Cabinet Construction 0C121 Industrial version *
Cabinet Construction C121 Marine construction
Channeled Air 0C128 none *
Channeled Air C128 Cooling air through bottom
Standards 0C129 IEC *
Standards C129 UL-approved components
Standards C134 CSA-approved components
Channeled Air Outlet 0C130 none *
Channeled Air Outlet C130 Channeled Air Outlet
Braking Unit Type D150 Chopper only *
Braking Unit Type D151 Chopper + braking resistor
EMC 0E210 none *
23

EMC E210 2nd environment
Wiring materials 0G330 Standard wire material
Wiring materials G330 Halogen free wiring
Cabinet Options G300 Cabinet heater
Control Voltage for Relays G304 115 V AC
and Fans
Control Voltage for Relays G320 230 V AC *
and Fans
Terminals for External 0G307 none *
Control Voltage
Terminals for External G307 Terminals for External Control Voltage
Control Voltage
DC Bus Material G314 Aluminium *
DC Bus Material G315 Tin plated copper
Power Cabling Exit H352 Bottom exit *
Power Cabling Exit H353 Top exit
Cable gland 0H365 none *
Cable gland H358 Cable gland plates (Steel 3 mm, undrilled)
Cable gland H364 Cable gland plates (Aluminium 3 mm, undrilled)
Cable gland H365 Cable gland plates (Brass 6 mm, undrilled)
Control Cabling H367 Bottom exit *
Control Cabling H368 Top exit
CDP-panel 0J400 none *
CDP-panel J400 Control panel CDP 312R
LMD-panel 0J401 none *
LMD-panel J401 Drive Monitoring Display
Panels 0J410 none *
Panels J410 Drive control panel connection kit
I/O-Options4 0L503 none *
I/O-Options4 L503 DDCS Communication 3
I/O-Options5 0L504 none *
I/O-Options5 L504 Additional RMIO terminal block
FieldBus1 0K451 none *
FieldBus1 K451 RDNA-01 (DeviceNet™)
FieldBus1 K452 RLON-01 (LONWORKS®)
FieldBus1 K454 RPBA-01 (PROFIBUS)
FieldBus1 K458 RMBA-01 (Modbus)
FieldBus1 K462 RCNA-01 (ControlNet™)
FieldBus1 K466 RETA-01 (Ethernet)
FieldBus1 K457 RCAN-01 (CANopen)
FieldBus2 0ZK458 none *
24

FieldBus2 ZK458 RMBA-01 (Modbus adapter) with other fieldbus
FieldBus3 0K453 none *
Specialities P902 Customised (additional information needed)
Inverter Controlled Fan 0C126 Not selected
Inverter Controlled Fan C126 Selected (available for frame R8i modules only) *
Documentation Languages R700 English *
Documentation Languages R701 German
Documentation Languages R702 Italian
Documentation Languages R703 Dutch
Documentation Languages R704 Danish
Documentation Languages R705 Swedish
Documentation Languages R706 Finnish
Documentation Languages R707 French
Documentation Languages R708 Spanish
Documentation Languages R709 Portuguese (spoken in Portugal)
Documentation Languages R710 Portuguese (spoken in Brazil)
Documentation Languages R711 Russian
Documentation Languages R712 Chinese
Drive Window Option Z040 Drive Window selected (Plastic + Silica fibre)
DriveBus Branching unit 0Z050 none *
DriveBus Branching unit Z050 NDBU-95
25
Type code of the brake module

The type code of the brake module is indicated on the type designation label,
attached on the module. The type code contains a summary of the configuration of
the module. The first digits from left express the basic configuration e.g.
ACS800-104-0400-7.
Basic code
Digit Name/Description Alternatives
1…6 Product series ACS800
8…10 Product type 104 inverter, supply and brake module
12…15 Size 0175…0580
17 Voltage rating 3 – Voltage range 380…415 V AC
Option codes
Ident. Alternatives Description
letter
C +C126 Speed-controlled cooling fan supplied from the DC bus. Available
for frame R8i only.
E +E205 Internal output (du/dt) filter. Not available for frame R7i. Standard
with frame R8i.
G +G304 115 V AC control voltage. Frame R7i only. (This option is not
applicable to frame R8i which is suitable for 230/115 V.)
V +V991 Current hardware variant. Frame R8i only.
In brake units consisting of parallel-connected frame R8i modules,
either all or none of the modules must have this option. In a single-
module unit, modules with or without this code are
interchangeable.
26
27

This chapter instructs in planning the installation of the ACS800-607 brake unit.
Note: The installation must always be designed and made according to applicable
local laws and regulations. ABB does not assume any liability whatsoever for any
installation which breaches the local laws and/or other regulations. Furthermore, if
the recommendations given by ABB are not followed, the drive may experience
problems that the warranty does not cover.
Mechanical installation
The brake unit forms one section in the cabinet line-up. For the mechanical
installation of the line-up see the manual ACS800 Liquid-cooled Multidrive
Mechanical Installation (3AFE68715466 [English]).
For the installation of the brake resistors, follow the instructions provided by the
resistor manufacturer.
Generic guidelines for the electrical installation

The generic guidelines for planning the electrical installation (selecting cables,
routing cables, etc.) of the liquid-cooled multidrive are given in the manual ACS800
Liquid-cooled Multidrive Modules, Planning the Electrical Installation
Short-circuit protection
The brake unit is equipped with input and output fuses to protect the chopper, the
resistor and the brake circuit cables in a cable short-circuit situation.
Thermal overload protection

The brake chopper protects itself and the resistor cables against thermal overload
when the cables are dimensioned according to the nominal current of the chopper.
The brake control program includes a resistor and resistor cable thermal protection
function which can be tuned by the user. See the Brake Control Program Firmware
Manual (3AFE68835631 [English]).

28
Protection in brake chopper failure and brake resistor overheat situations
Instruction
Protect against brake resistor overtemperature and brake chopper failure situations
as follows:
• Equip each brake resistor with an overtemperature sensor of its own.
• Wire the sensors to digital input DI1 on the RMIO board.
• Wire relay output RO1 to the main breaker and always switch off the power
supply to the drive when relay output RO1 is de-energized. Note: This is the only
way to guarantee safe operation since in case of a chopper failure the chopper is
unable to disconnect the resistor from the intermediate DC circuit.
• Set parameter 16.11 SUPPLY NETWORK to according to the electrical power
system.
For more information, see Brake Control Program Firmware Manual
How the protection differs in TN and IT electrical power systems

When TN (grounded) electrical power system is selected with Brake Control
Program parameter 16.11 SUPPLY NETWORK, RMIO board relay output RO1 is
de-energized when a brake resistor is overheated. When IT (ungrounded) electrical
power system is selected with the parameter, relay output RO1 is de-energized
when a brake resistor is overheated and the intermediate DC circuit voltage is
simultaneously at an exceptionally low level.
Selecting the brake resistors

The brake units must be equipped with brake resistors. The brake resistors dissipate
the surplus energy conducted by the choppers. Select the brake resistors according
to the resistor specification given in chapter Technical data.
Consider also the following:
• Each brake module phase must feed a resistor of its own.
• The resistance (R) of each brake resistor must be equal to the value specified.
Never use resistance values below the specified value.
• The resistor must withstand the specified brake cycles.
• Each resistor must be equipped with an overtemperature sensor.
WARNING! ABB is not responsible for customer resistor selection or protection of

the resistor.

29
Placing the brake resistors

Select the place for the resistor considering the resistor cooling and the maximum
allowed cable length.
Cooling: The resistor dissipates the braking energy to its surroundings. Arrange the
cooling of the resistor in a way that:
• no danger of overheating is caused to the resistor or nearby materials.
• the temperature of the room the resistor is located in does not exceed the allowed
maximum.
Supply the resistor with cooling air/water according to the resistor manufacturer’s
instructions.
WARNING! Exhaust air of an air-cooled brake resistor is hot. Keep flammable

materials away from the exhaust vents. If the exhaust vents are connected to a
ventilation system, ensure that the material withstands high temperatures.
Installing the brake resistors

Follow the instructions provided by the resistor manufacturer.
Selecting and routing the brake resistor cables

See Technical data for the cable specification.
Minimizing electromagnetic interference
Follow these rules in order to minimise electromagnetic interference caused by the
rapid current changes in the cables:
• The braking power line must be completely shielded, either by cable shield or
metallic enclosure. Unshielded single-core cable can only be used if routed inside
a cabinet that efficiently suppresses the radiated RFI emissions.
• The cables should be installed away from other cable routes.
• Long parallel runs with other cables should be avoided. The minimum parallel
cabling separation distance should be 0.3 metres.
• The cables should cross at right angles.
Maximum cable length
The maximum length of the resistor cable is 300 m. However, keep the cable as
short as possible in order to minimise the EMC emissions and stress on chopper
IGBTs. The longer the cable the higher the EMC emissions. The longer the cable the
higher the inductive load and voltage peaks over the IGBT semiconductors of the
brake chopper.

30
EMC compliance of the complete installation
Note: ABB has not verified that the EMC requirements are fulfilled with external
user-defined brake resistors and cabling. The EMC compliance of the complete
installation must be considered by the user.

31
Installation

This chapter instructs in installation of ACS800-607 brake unit.
Safety
Safety
WARNING! Only qualified electricians are allowed to carry out the installation.
All safety instructions must be followed during the work. See the manual ACS800
Multidrive and Multidrive Modules Safety Instructions (3AFE64760432 [English]).
Ignoring the safety instructions can cause injury or death, or damage to the
equipment.
WARNING! Make sure that the drive system is disconnected from the input power
during installation. If the drive system is already connected to the mains, wait for
5 min after disconnecting mains power. Measure the voltage between the DC
busbars/cables and earth with a multimeter (impedance at least 1 Mohm) to ensure
that the drive system is discharged before beginning work.
WARNING! Circuit boards contain components sensitive to electrostatic discharge

(ESD). Wear an earthing wrist band when handling the boards. Do not touch the
boards unnecessarily.
Mechanical installation
The brake unit forms one section in the cabinet line-up. For the mechanical
installation of the line-up see ACS800 Multidrive Mechanical Installation
For the installation of brake resistors, follow the instructions provided by the resistor
manufacturer.
Installation
32
Checking the insulation of the resistor circuit

Every brake unit and module has been tested for insulation between the main circuit
and the chassis (2500 V rms 50 Hz for 1 second) at the factory. Therefore, do not
make any voltage tolerance or insulation resistance tests e.g. hi-pot or megger, on
the brake units or modules.
Check the insulation of the brake resistor assembly as follows:
1. Check that the resistor cable is connected to the resistor, and disconnected from
brake unit output terminals Rx.1 and Rx.2
2. At the brake unit end, connect the R+ and R- conductors of the resistor cable
together. Measure the insulation resistance between the combined conductors
and the PE conductor/shield by using a measuring voltage of 1 kV DC. The
insulation resistance must be higher than 1 Mohm.
R+
R-
ohm
PE
Installation
33
Connecting the resistor cables
WARNING! With aluminum cables, apply grease to the stripped conductors before
attaching them to non-coated aluminum cable lugs. Obey the grease manufacturer’s
instructions. Aluminum-aluminum contact can cause oxidation of the contact
surfaces.
1. Open the door of the brake module cubicle: Unlock the handle, release it from the
holder and turn upwards to release the door locking mechanism.
2. Remove the shroud that protects the output busbars and cable entries.
3. Units with bottom entry/exit: Unplug the socket of the cooling fan and remove the
cooling fan.
4. Lead the cables into the inside of the cubicle. For minimum radio frequency
interference and motor bearing current, ground the cable shield 360° at the lead-
through.
5. Connect the cables as follows:
• Cut the cables to suitable length. Strip the cables and conductors. Fasten the
cable lugs to the conductor ends.
• Twist the cable shields into bundles and connect them to the cabinet PE
busbar.
• Connect the conductors to the terminals as shown on the diagram below.
• Tighten the resistor and PE conductors to 70 N·m (50 lbf·ft) torque.
6. Plug in the fan power supply and refit the fan.
7. Refit the shroud removed earlier and close the door.
Installation
34
Connection diagram – three-conductor cable
DC+
DC -
F6.1 F6.2
F6.11
ACS800-104
U2 V2 W2
R1.1 R2.1 R3.1

PE
R1.2
R2.2
Cabinet PE
R3.2
ACS800-607
Grommet in IP54 units

only
Grounding at the cable lead-

through
Notes:
For selection of the resistor cables, see section Resistor cable on page 54.
Pay special attention to the grounding of the cable. 360° earthing is to be used at cable entries.
For the resistor cable terminal sizes, cabinet lead-through sizes and tightening torques, see section Resistor cable
connection and lead-through data on page 55.
Tightening torque is 70 N·m (52 lbf·ft).
For resistor overheating protection, see page 20.
WARNING! Never connect the output terminals of the brake chopper together. It
short-circuits the chopper and will damage it.
Installation
35
Connection diagram – four-conductor cable
DC+
DC -
F6.1 F6.2
ACS800-104 F6.11
U2 V2 W2
R1.1 R2.1 R3.1 PE

R1.2
R2.2
Cabinet PE
R3.2
ACS800-607
Grommet in IP54 units

only
Grounding at the cable lead-

through
Notes:
For selection of the resistor cables, see section Resistor cable on page 54.
Pay special attention to the grounding of the cable. 360° earthing is to be used at cable entries.
For the resistor cable terminal sizes, cabinet lead-through sizes and tightening torques, see section Resistor cable
connection and lead-through data on page 55.
Tightening torque is 70 N·m (52 lbf·ft).
For resistor overheating protection, see page 20.
WARNING! Never connect the output terminals of the brake chopper together. It
short-circuits the chopper and will damage it.
Installation
36
Wiring the fault indication from relay output RO1 to the main breaker
A principle of wiring the fault indication from relay output RO1 to the main breaker
control is shown below.
L1 L2 L3
1
0 K 1
S1
2
13 1 3 5
K1
S1 1 3
14 2 4 6 Main breaker
1 2 4
0 K
1 3
RMIO
K × × X25
1 × 2
0
3
K1
Installation
37
Control cable connection procedure

WARNING! Before start, read and follow the safety instructions given in ACS800 Liquid-cooled
Multidrive and Multidrive Modules Safety Instructions (3AFE68715318 [English]). Ignoring the
instructions can cause physical injury or death, or damage to the equipment.
Open the cabinet door(s).
Remove any shrouds that limit access to the cable lead-throughs and cable trunking.
Run the cables into the inside of the cabinet through the grommets provided.
Top entry units only: If several cables need to be run through one grommet, use Loctite 5221 (cat. no.
25551) under the grommet to seal the cable entry.
Units with EMI conductive cushions only:
Run the cables between the cushions as shown below. Strip the cable at this location to enable proper
connection of the bare shield and the cushions. Tighten the cushions firmly onto the cable shields.
Side view
Strain relief EMI conductive
cushions
Grommet Lead-through plate
If the outer surface of a cable shield is non-conductive, turn the shield inside out as shown below and
apply copper foil to keep the shielding continuous. Do not cut the grounding wire (if present).
Stripped cable Conductive surface of Stripped part covered

the shield exposed with copper foil
Copper foil
Cable shield Shielded twisted pair
Grounding wire
On top entry units, sort the cables so that the thinnest and thickest cables are at opposite ends of the
opening.
Top view
Thickest cable Thinnest cable
Installation
38
Run the cables to the appropriate terminals. Wherever possible, use the existing cable trunking in the
cabinet. Use sleeving wherever the cables are laid against sharp edges.
Note: When running cables to the swing-out frame, leave some slack in the cable at the hinge to allow the
frame to open fully. Tie the cables to the cable supports wherever necessary.
Cut the cables to suitable length. Strip the cables and conductors.
Twist the cable shields into bundles and connect them to the ground terminal nearest to the terminal block.
Keep the unshielded portion of the cables as short as possible.
Connect the conductors to appropriate terminals (see the circuit diagrams delivered with the unit).
Refit any shrouds removed earlier. Close the cabinet door(s).
Installation of optional modules and PC
WARNING! Read and follow the safety instructions, given in ACS800 Multidrive and
Multidrive Modules Safety Instructions (3AFE64760432 [English]). Ignoring the
instructions can cause physical injury or death, or damage to the equipment.
PC connection
Connect PC to CH3 of RDCO board via a fibre optic link. RDCO is attached to an
option slot of the RDCU unit. See also Fibre optic links below.
Optional modules
Insert optional modules (such as fieldbus adapters) into the optional module slots of
the RDCU unit and secure with two screws. The slots on the RDCU unit are
described in Power connections and control interfaces on page 19. See also the
appropriate optional module manual for information on the cable connections.
Cabling of fieldbus modules
Module
Keep unshielded portion as
short as possible
Shield
1
2
3
4
To nearest PE terminal
Installation
39
Fibre optic links

DDCS fibre optic links are provided by RDCO module for PC tools, AIMA I/O module
adapter and fieldbus adapter modules of type Nxxx. See the RDCO User’s Manual
(3AFE64492209 [English]) for the details. Observe colour coding when installing
fibre optic cables. Blue connectors go to blue terminals, and grey connectors to grey
terminals.
When installing multiple devices on the same channel, connect them in a ring.
Installation
40
Installation
41
Start-up

This chapter describes the start-up procedure of the brake unit. The information is
valid for cabinet-installed brake unit types ACS800-607, and for ACS800-604 brake
modules when equipped with similar auxiliary devices.
WARNING! The work described in this chapter must only be carried out by a
qualified electrician. The directions given in ACS800 Multidrive and Multidrive
Modules Safety Instructions (3AFE64760432 [English]) must be followed.
Neglecting the safety instructions can cause injury or death.
Start-up checklist
Action Additional information
Preliminary actions
WARNING! Ensure that the disconnector of the supply transformer is locked to open position, i.e. no voltage is, or
can be, connected to the drive inadvertently. Check also by measuring that there is no voltage connected.
Check that the mechanical and electrical installation of the brake resistor See chapters Planning the installation
has been inspected and is OK. and Installation.
Check that the insulation of the resistor circuit has been measured and is See section Checking the insulation
OK. of the resistor circuit on page 32.
Ensure that the surroundings and the inside of the cabinet are free from
dust and loose objects like cable trimmings and other waste left from the
installation.
Check that the drive is ready for the brake unit start-up, i.e.: See the appropriate manuals from the
• The drive has been installed according to the instructions given in the list on the inside of the front cover.
hardware manual.
• The supply unit has been commissioned according to the instructions
given in the appropriate supply unit manual.
• The inverter units have been commissioned according to the
instructions given in the hardware manual and appropriate firmware
manual.
Close all cabinet doors.
Start-up
42
Action Additional information

Power switch-on
Close the disconnector of the supply transformer.
Switch on power to the drive and start the supply unit.
Setting the parameters
Set the parameters of group 36 CABLE/BR PROTECT. See Brake Control Program Firmware
Manual (3AFE68835631 [English])
Set parameter 16.11 SUPPLY NETWORK.
Set parameter 30.02 DI1 TRIP DELAY.
Operational check
Ensure that it is safe to run the drive. Start the drive and increase the Use a low speed at first.
rotation speed of a motor to be braked.
Deactivate the overvoltage controllers of all inverters (parameter For the drive parameter settings, see
30.23 OVERVOLTAGE CTR in System Control Program). the appropriate firmware manual.
Ensure that the stop mode of the motor to be braked is ramp stop and set Use a relatively long deceleration
the deceleration time (parameters 21.03 STOP FUNCTION and time at first.
22.02 DECEL TIME in System Control Program).
Check that the braking operates OK by stopping the motor and See Brake Control Program Firmware
simultaneously monitoring the intermediate circuit DC voltage with the Manual (3AFE68835631 [English]).
DriveWindow PC tool. View the Brake Control Program and check that Unsuccessful braking:
• the value of parameter 1.05 SW FREQ ACT is in the range of • brake chopper or inverter(s) trips
800…1200 Hz, on overvoltage,
• the value of parameter 23.06 BC HIGH LEVEL > the value of • or the inverter automatically
parameter 1.10 DC VOLTAGE > the value of parameter 23.05 BC prolongs the deceleration i.e. does
LOW LEVEL. not meet the deceleration time
Note: New brake resistors may be coated with storage grease. As the defined by parameter
brake chopper operates for the first time, the grease burns off and may 22.02 DECELER TIME,
produce some smoke. Make sure there is proper ventilation. • or the inverter meets the power limit
defined by parameter
20.18 P GENERATING LIM.
Repeat the stop sequence a few times with higher rotation speeds and
shorter deceleration times.
Restore parameter 30.23 OVERVOLTAGE CTR to the original value.
Start-up
43
Fault tracing

This chapter instructs in interpreting the LED indications of the brake unit.
Information on the warning and fault messages of the drive is given in the Brake
Control Program Firmware Manual (3AFE68835631 [English]).
LEDs of the brake unit
Location LED Indication
RMIO board (RDCU drive control Red Brake chopper in fault state.
unit)
Green The power supply on the board is OK.
Control panel mounting platform Red Brake chopper in fault state.
(with the control panel removed)
Green The main +24 V power supply for the control panel and the
RMIO board is OK.
AINT board (visible through the V204 (green) +5 V voltage of the board is OK.
transparent cover on the front of the
V309 (red) -
brake modules)
V310 (green) IGBT control signal transmission to the gate driver control
boards is enabled.
APBU board “RXD” led Data is being received from RDCU drive control unit.
“TXD” led Data is being sent to RDCU drive control unit.
“BAT” led Memory backup battery voltage is OK.
“PWR” led 5 V power to on-board logic is OK.
Fault tracing
44
Fault tracing
45
Maintenance
See ACS800-107 Inverter Unit Hardware Manual (3AFE68233453 [English]) for:

• preventive maintenance intervals of cooling fans and converter modules
• instructions on how to replace the cooling fans and converter modules.
Reduced run capability

If one of parallel-connected brake modules must be taken out of the cabinet for
service, it is possible to continue operation using the remaining modules at reduced
power. The number of the remaining parallel-connected brake modules is defined
with parameter 16.10 INT CONFIG USER. Half of the original number of the
modules can be removed. For more information, see Brake Control Program
Firmware Manual (3AFE68835631 [English]) or contact your local ABB
representative.
Note: When a brake unit with parallel-connected brake modules is equipped with
one RMIO board only, a fault in one brake module trips the whole brake unit.
In units with brake modules equipped with their own RMIO boards, only the faulted
brake module trips and the drive continues running with the remaining brake
modules without parameter settings. However, when relay output RO1 is de-
energized, the main breaker of the whole drive must be opened. See page 36. For
more information on the protection, see the Brake Control Program Firmware
Manual (3AFE68835631 [English]).
Maintenance
46
Maintenance
47
Technical data

This chapter contains the technical data for the ACS800-607 brake units.
Ratings
The rating tables are given below.
Unit type Frame Resistor values Ratings with Rmin
size No-overload use Cycle load (1min/5min)
Rmin Rmax Idc Irms Pcontmax Imax Idc Irms Pbr
Ohm Ohm A DC A DC kW A DC A DC A DC kW
UN=400 V
ACS800-607-0250-3 R7i 3.5 4.1 390 155 250 185 500 176 320
ACS800-607-0500-3 R8i 1.7 2.1 781 310 500 370 999 351 640
ACS800-607-0750-3 R8i 1.2 1.4 1171 465 750 555 1499 527 960
ACS800-607-1000-3 2×R8i 1.7 2.1 1562 621 1000 740 1998 702 1290
ACS800-607-1510-3 2×R8i 1.2 1.4 2342 931 1510 1110 2997 1053 1930
ACS800-607-2260-3 3×R8i 1.2 1.4 3514 1396 2260 1665 4496 1580 2890
ACS800-607-3010-3 4×R8i 1.2 1.4 4685 1862 3010 2220 5994 2106 3860
ACS800-607-3770-3 5×R8i 1.2 1.4 5856 2327 3770 2775 7493 2633 4820
UN=500 V
ACS800-607-0310-5 R7i 4.3 5.2 390 155 310 185 500 176 400
ACS800-607-0630-5 R8i 2.2 2.6 781 310 630 370 999 351 800
ACS800-607-0940-5 R8i 1.4 1.7 1171 465 940 555 1499 527 1210
ACS800-607-1260-5 2×R8i 2.2 2.6 1562 621 1260 740 1998 702 1610
ACS800-607-1880-5 2×R8i 1.4 1.7 2342 931 1880 1110 2997 1053 2410
ACS800-607-2830-5 3×R8i 1.4 1.7 3514 1396 2830 1665 4496 1580 3620
ACS800-607-3770-5 4×R8i 1.4 1.7 4685 1862 3770 2220 5994 2106 4820
ACS800-607-4710-5 5×R8i 1.4 1.7 5856 2327 4710 2775 7493 2633 6030
UN=690 V
ACS800-607-0430-7 R7i 6.0 7.1 390 155 430 185 500 176 550
ACS800-607-0870-7 R8i 3.0 3.6 781 310 870 370 999 351 1110
ACS800-607-1300-7 R8i 2.0 2.4 1171 465 1300 555 1499 527 1660
ACS800-607-1730-7 2×R8i 3.0 3.6 1562 621 1730 740 1998 702 2220
ACS800-607-2600-7 2×R8i 2.0 2.4 2342 931 2600 1110 2997 1053 3330
ACS800-607-3900-7 3×R8i 2.0 2.4 3514 1396 3900 1665 4496 1580 4990
ACS800-607-5200-7 4×R8i 2.0 2.4 4685 1862 5200 2220 5994 2106 6650
ACS800-607-6500-7 5×R8i 2.0 2.4 5856 2327 6500 2775 7493 2633 8320
00184674.xls / H.29
Technical data
48
Brake unit type Module Resistor values Ratings with Rmax

frame No-overload use Cycle load (1min/5min)
size Rmin Rmax Idc Irms Pcontmax Imax Idc Irms Pbr
Ohm Ohm A DC A DC kW A DC A DC A DC kW
UN=400 V
ACS800-607-0250-3 R7i 3.5 4.1 390 143 250 156 422 148 270
ACS800-607-0500-3 R8i 1.7 2.1 781 282 500 312 827 291 530
ACS800-607-0750-3 R8i 1.2 1.4 1171 424 750 468 1241 436 800
ACS800-607-1000-3 2×R8i 1.7 2.1 1562 565 1000 625 1655 581 1060
ACS800-607-1510-3 2×R8i 1.2 1.4 2342 847 1510 937 2482 872 1600
ACS800-607-2260-3 3×R8i 1.2 1.4 3514 1271 2260 1405 3723 1308 2400
ACS800-607-3010-3 4×R8i 1.2 1.4 4685 1694 3010 1874 4964 1744 3190
ACS800-607-3770-3 5×R8i 1.2 1.4 5856 2118 3770 2342 6205 2180 3990
UN=500 V
ACS800-607-0310-5 R7i 4.3 5.2 390 143 310 156 422 148 340
ACS800-607-0630-5 R8i 2.2 2.6 781 284 630 312 835 293 670
ACS800-607-0940-5 R8i 1.4 1.7 1171 430 940 468 1277 449 1030
ACS800-607-1260-5 2×R8i 2.2 2.6 1562 568 1260 625 1671 587 1340
ACS800-607-1880-5 2×R8i 1.4 1.7 2342 860 1880 937 2555 898 2060
ACS800-607-2830-5 3×R8i 1.4 1.7 3514 1289 2830 1405 3832 1347 3080
ACS800-607-3770-5 4×R8i 1.4 1.7 4685 1719 3770 1874 5110 1795 4110
ACS800-607-4710-5 5×R8i 1.4 1.7 5856 2149 4710 2342 6387 2244 5140
UN=690 V
ACS800-607-0430-7 R7i 6.0 7.1 390 143 430 156 422 148 470
ACS800-607-0870-7 R8i 3.0 3.6 781 283 870 312 833 293 920
ACS800-607-1300-7 R8i 2.0 2.4 1171 425 1300 468 1249 439 1390
ACS800-607-1730-7 2×R8i 3.0 3.6 1562 567 1730 625 1665 585 1850
ACS800-607-2600-7 2×R8i 2.0 2.4 2342 850 2600 937 2498 878 2770
ACS800-607-3900-7 3×R8i 2.0 2.4 3514 1275 3900 1405 3746 1316 4160
ACS800-607-5200-7 4×R8i 2.0 2.4 4685 1700 5200 1874 4995 1755 5540
ACS800-607-6500-7 5×R8i 2.0 2.4 5856 2125 6500 2342 6244 2194 6930
00184674.xls / H.29
Technical data
49
Symbols
Resistor
Rmin Minimum allowed resistance value of the brake resistor per one phase of the brake module
Rmax Maximum resistance value of the brake resistor per one phase of the brake module
Note: Connect one resistor per brake module phase. For example, a brake unit of frame size
2×R8i includes two brake modules -> 2 × 3 resistors are needed.
Peak brake current
Imax Peak brake current (DC) per chopper module phase
No-overload use
Pcont.max Maximum continuous braking power per brake unit
Imax
Irms
Pbrcont
0 0
Cyclic load (1 min / 5 min)

Irms Total rms DC current per brake unit phase during a period of 1 minute with braking power
Pbr
Pbr Short term braking power per brake unit allowed for one minute every 5 minutes
Imax
Irms
Pbr
0 0
1 min 4 min
1 min 4 min
Peak brake current

Example: Brake unit with two parallel brake modules
DC+
DC -
Idc1 Idc2
ACS800-104 ACS800-104
U2 V2 W2 U2 V2 W2
Irms1 Irms2
Idc = Idc1 + Idc2

Irms = Irms1 + Irms2
Technical data
50
Derating
The load capacity (current and power) decreases if the installation site altitude
exceeds 1000 metres (3300 ft), or if the ambient temperature exceeds 40 °C
(104 °F).
Temperature derating
In the temperature range +40 °C (+104 °F) to +50 °C (+122 °F) the rated output
current is decreased 1% for every additional 1 °C (1.8 °F). The output current is
calculated by multiplying the current given in the rating table by the derating factor.
Example If the ambient temperature is +50 °C (+122 °F) the derating factor is
100% - 1 · 10 °C = 90% or 0.90. The output current is then 0.90 · I2N or 0.90 · I2hd.
Note: Icont.max rating is not allowed above 40 °C (104 °F).
Altitude derating
In altitudes from 1000 to 4000 m (3300 to 13123 ft) above sea level, the derating is
1% for every 100 m (328 ft). For a more accurate derating, use the DriveSize PC
tool.
Technical data
51
Input and output voltages

Typical input and output voltages are listed below.
UN (V AC) Input voltage (DC) Output voltage (DC)
400 513…587 V DC 3 × 0…587 V DC
500 513…707 V DC 3 × 0…707 V DC
690 709…976 V DC (UL, CSA: 848 V DC) 3 × 0…976 V DC (UL, CSA: 848 V DC)
00184674.xls / H.40
Type equivalences
Brake unit type Basic brake module
No. and
Type
size
UN = 400 V
ACS800-607-0250-3 ACS800-104-0175-3 R7i
ACS800-607-0500-3 ACS800-104-0320-3 R8i
ACS800-607-0750-3 ACS800-104-0510-3 R8i
ACS800-607-1000-3 ACS800-104-0320-3 2×R8i
ACS800-607-1510-3 ACS800-104-0510-3 2×R8i
ACS800-607-2260-3 ACS800-104-0510-3 3×R8i
ACS800-607-3010-3 ACS800-104-0510-3 4×R8i
ACS800-607-3770-3 ACS800-104-0510-3 5×R8i
UN = 500 V
ACS800-607-0310-5 ACS800-104-0215-5 R7i
ACS800-607-0630-5 ACS800-104-0400-5 R8i
ACS800-607-0940-5 ACS800-104-0610-5 R8i
ACS800-607-1260-5 ACS800-104-0400-5 2×R8i
ACS800-607-1880-5 ACS800-104-0610-5 2×R8i
ACS800-607-2830-5 ACS800-104-0610-5 3×R8i
ACS800-607-3770-5 ACS800-104-0610-5 4×R8i
ACS800-607-4710-5 ACS800-104-0610-5 5×R8i
UN = 690 V
ACS800-607-0430-7 ACS800-104-0215-7 R7i
ACS800-607-0870-7 ACS800-104-0400-7 R8i
ACS800-607-1300-7 ACS800-104-0580-7 R8i
ACS800-607-1730-7 ACS800-104-0400-7 2×R8i
ACS800-607-2600-7 ACS800-104-0580-7 2×R8i
ACS800-607-3900-7 ACS800-104-0580-7 3×R8i
ACS800-607-5200-7 ACS800-104-0580-7 4×R8i
ACS800-607-6500-7 ACS800-104-0580-7 5×R8i
00184674.xls / H.29
Technical data
52
Dimensions, noise, losses and cooling air flow

Brake unit type Dimensions Noise level Losses Cool-
Height Height Space Width 1 Width 2 Depth Weight DOL Avg ing air
1 2 above flow
mm mm mm mm mm mm kg dB dB kW m 3/h
UN = 400 V
ACS800-607-0250-3 2130 2320 400 400 400 644 250 72 - 1.8 800
ACS800-607-0500-3 2130 2320 400 500 700 644 380 72 60 3.5 1280
ACS800-607-0750-3 2130 2320 400 500 700 644 380 72 60 5.3 1280
ACS800-607-1000-3 2130 2320 400 1000 1400 644 760 74 62 7.0 2560
ACS800-607-1510-3 2130 2320 400 1000 1400 644 760 74 62 10.6 2560
ACS800-607-2260-3 2130 2320 400 1500 2100 644 1140 76 64 15.8 3840
ACS800-607-3010-3 2130 2320 400 2000 2800 644 1520 76 64 21.1 5120
ACS800-607-3770-3 2130 2320 400 2500 3500 644 1900 77 65 26.4 6400
UN = 500 V
ACS800-607-0310-5 2130 2320 400 400 400 644 250 72 - 1.7 800
ACS800-607-0630-5 2130 2320 400 500 700 644 380 72 60 3.5 1280
ACS800-607-0940-5 2130 2320 400 500 700 644 380 72 60 5.3 1280
ACS800-607-1260-5 2130 2320 400 1000 1400 644 760 74 62 7.1 2560
ACS800-607-1880-5 2130 2320 400 1000 1400 644 760 74 62 10.5 2560
ACS800-607-2830-5 2130 2320 400 1500 2100 644 1140 76 64 15.8 3840
ACS800-607-3770-5 2130 2320 400 2000 2800 644 1520 76 64 21.1 5120
ACS800-607-4710-5 2130 2320 400 2500 3500 644 1900 77 65 26.4 6400
UN = 690 V
ACS800-607-0430-7 2130 2320 400 400 400 644 250 72 - 2.0 800
ACS800-607-0870-7 2130 2320 400 500 700 644 380 72 60 4.0 1280
ACS800-607-1300-7 2130 2320 400 500 700 644 380 72 60 5.9 1280
ACS800-607-1730-7 2130 2320 400 1000 1400 644 760 74 62 7.9 2560
ACS800-607-2600-7 2130 2320 400 1000 1400 644 760 74 62 11.9 2560
ACS800-607-3900-7 2130 2320 400 1500 2100 644 1140 76 64 17.8 3840
ACS800-607-5200-7 2130 2320 400 2000 2800 644 1520 76 64 23.7 5120
ACS800-607-6500-7 2130 2320 400 2500 3500 644 1900 77 65 29.7 6400
00184674.xls / H.29
Height 1 = Height of unit with degree of protection IP22 and IP42

Height 2 = Height of unit with degree of protection IP54
Width 1 = Width of the unit with bottom cable entry
Width 2 = Width of the unit with top cable entry
Technical data
53
Fuses
DC+ and DC- fuses Resistor fuses
Brake unit type Type by Type by Ferraz Type by Type by Ferraz
Qty Qty
Bussmann Shawmut Bussmann Shawmut
UN = 400 V
ACS800-607-0250-3 170M6544 PC93UD18C630TF 2 170L5117 PC93UF15C315TF 3
ACS800-607-0500-3 170M6544 PC93UD18C630TF 4 170L9868 PC93UD18C630TF 3
ACS800-607-0750-3 170M6548 PC93UD17C1000TF 4 170M6734 PC93UD18C850TF 3
UN = 500 V
UN = 690 V
3AXD00000184674 J20
Technical data
54
Resistor cable
The table below gives copper cable types. Cable sizing is based on max. 9 cables
laid on a cable ladder side by side, three ladder type trays one on top of the other,
ambient temperature 30 °C, PVC insulation, surface temperature 70 °C and 90 °C
(EN 60204-1 and IEC 60364-5-2/2001). For other conditions, size the cables
according to local safety regulations, appropriate input voltage and the load current
of the drive. Irms dim is the dimensioning current.
Brake unit type No. and size Irms dim Cable data*
of modules Cable, T=70 °C Cable, T=90 °C
2
A mm mm2
UN = 400 V
ACS800-607-0250-3 R7i 186 3×(3×120+70) 3×(3×95+50)
ACS800-607-0500-3 R8i 372 3×(2×(3×120+70)) 3×(3×240+120)
ACS800-607-0750-3 R8i 559 3×(2×(3×240+120)) 3×(2×(3×150+70))
ACS800-607-1000-3 2×R8i 745 2×(3×(2×(3×120+70))) 2×(3×(3×240+120))
ACS800-607-1510-3 2×R8i 1117 2×(3×(2×(3×240+120))) 2×(3×(2×(3×150+70)))
ACS800-607-2260-3 3×R8i 1676 3×(3×(2×(3×240+120))) 3×(3×(2×(3×150+70)))
ACS800-607-3010-3 4×R8i 2234 4×(3×(2×(3×240+120))) 4×(3×(2×(3×150+70)))
ACS800-607-3770-3 5×R8i 2793 5×(3×(2×(3×240+120))) 5×(3×(2×(3×150+70)))
UN = 500 V
ACS800-607-0310-5 R7i 186 3×(3×120+70) 3×(3×95+50)
ACS800-607-0630-5 R8i 372 3×(2×(3×120+70)) 3×(3×240+120)
ACS800-607-0940-5 R8i 559 3×(2×(3×240+120)) 3×(2×(3×150+70))
ACS800-607-1260-5 2×R8i 745 2×(3×(2×(3×120+70))) 2×(3×(3×240+120))
ACS800-607-1880-5 2×R8i 1117 2×(3×(2×(3×240+120))) 2×(3×(2×(3×150+70)))
ACS800-607-2830-5 3×R8i 1676 3×(3×(2×(3×240+120))) 3×(3×(2×(3×150+70)))
ACS800-607-3770-5 4×R8i 2234 4×(3×(2×(3×240+120))) 4×(3×(2×(3×150+70)))
ACS800-607-4710-5 5×R8i 2793 5×(3×(2×(3×240+120))) 5×(3×(2×(3×150+70)))
UN = 690 V
ACS800-607-0430-7 R7i 186 3×(3×120+70) 3×(3×95+50)
ACS800-607-0870-7 R8i 372 3×(2×(3×120+70)) 3×(3×240+120)
ACS800-607-1300-7 R8i 559 3×(2×(3×240+120)) 3×(2×(3×150+70))
ACS800-607-1730-7 2×R8i 745 2×(3×(2×(3×120+70))) 2×(3×(3×240+120))
ACS800-607-2600-7 2×R8i 1117 2×(3×(2×(3×240+120))) 2×(3×(2×(3×150+70)))
ACS800-607-3900-7 3×R8i 1676 3×(3×(2×(3×240+120))) 3×(3×(2×(3×150+70)))
ACS800-607-5200-7 4×R8i 2234 4×(3×(2×(3×240+120))) 4×(3×(2×(3×150+70)))
ACS800-607-6500-7 5×R8i 2793 5×(3×(2×(3×240+120))) 5×(3×(2×(3×150+70)))
Example
3×(2×(3×240+120))
This set for each resistor
One set is needed for each chopper phase.

3AXD00000184674 / H.29
Technical data
55
Resistor cable connection and lead-through data

See chapter Dimensional drawings.
Tightening torques for power connections

Screw size Torque
M5 3.5 N·m (2.6 lbf·ft)
M6 9 N·m (6.6 lbf·ft)
M8 20 N·m (14.8 lbf·ft)
M10 40 N·m (29.5 lbf·ft)
M12 70 N·m (52 lbf·ft)
M16 180 N·m (133 lbf·ft)
Efficiency
Approximately 98% at nominal power level
Cooling
Method Internal fans, flow direction from bottom to top
Filter material Inlet (door) Outlet (roof)
IP22/IP42 units Luftfilter airTex G150 –
IP54 units Luftfilter airComp 300-50 Luftfilter airTex G150
Free space See chapter Dimensional drawings.

around the unit
Cooling air flow See section Dimensions, noise, losses and cooling air flow above.
Degree of protection
IP22; IP42; IP54; IP54R (with air duct outlet)
Technical data
56
Ambient conditions
Environmental limits for the drive are given below. The drive is to be used in a heated, indoor,
controlled environment.
Operation Storage Transportation

installed for stationary use in the protective package in the protective package
0 to 4000 m (13123 ft) above sea - -

Installation site
level [above 1000 m (3281 ft),
altitude
see Derating on page 50].
0 to +50 °C (32 to 122 °F). No -40 to +70 °C -40 to +70 °C

Air temperature frost allowed. See Derating on (-40 to +158 °F) (-40 to +158 °F)
page 50.
5 to 95% Max. 95% Max. 95%

Relative
humidity No condensation allowed. Maximum allowed relative humidity is 60% in the presence of corrosive
gases.
No conductive dust allowed.

Contamination Boards without coating: Boards without coating: Boards without coating:
levels Chemical gases: Class 3C1 Chemical gases: Class 1C2 Chemical gases: Class 2C2
(IEC 60721-3-3, Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2
IEC 60721-3-2,
Boards with coating: Boards with coating: Boards with coating:
IEC 60721-3-1)
Chemical gases: Class 3C2 Chemical gases: Class 1C2 Chemical gases: Class 2C2
Solid particles: Class 3S2 Solid particles: Class 1S3 Solid particles: Class 2S2
Atmospheric 70 to 106 kPa 70 to 106 kPa 60 to 106 kPa

pressure 0.7 to 1.05 atmospheres 0.7 to 1.05 atmospheres 0.6 to 1.05 atmospheres
Max. 1 mm (0.04 in.) Max. 1 mm (0.04 in.) Max. 3.5 mm (0.14 in.)
Vibration (5 to 13.2 Hz), (5 to 13.2 Hz), (2 to 9 Hz),
(IEC 60068-2) max. 7 m/s2 (23 ft/s2) max. 7 m/s2 (23 ft/s2) max. 15 m/s2 (49 ft/s2)
(13.2 to 100 Hz) sinusoidal (13.2 to 100 Hz) sinusoidal (9 to 200 Hz) sinusoidal
Shock
Not allowed Max. 100 m/s2 (330 ft/s2), 11 ms Max. 100 m/s2 (330 ft/s2), 11 ms
(IEC 60068-2-27)
250 mm (10 in.) for weight under 250 mm (10 in.) for weight under
100 kg (220 lb) 100 kg (220 lb)
Free fall Not allowed
100 mm (4 in.) for weight over 100 mm (4 in.) for weight over
100 kg (220 lb) 100 kg (220 lb)
Technical data
57
Materials
Cabinet Hot-dip zinc-coated (thickness approx. 20 µm) sheet steel with polyester thermosetting powder coating
(thickness approx. 80 µm) on visible surfaces except back panel. Colour: RAL 7035 (light grey,
semigloss).
Busbars Tin- or silver-plated copper
Inverter modules • PC/ABS 2.5 mm, colour NCS 1502-Y (RAL 90021 / PMS 420 C)
• hot-dip zinc coated steel sheet 1.5 to 2 mm, thickness of coating 100 micrometres
• cast aluminium AlSi (R2i and R3i)
• extruded aluminium AlSi (R4i and R5i)
Fire safety of Insulating materials and non-metallic items mostly self-extinctive.

materials
(IEC 60332-1)
Packaging Frame of wood or plywood with PE-LD wrapping and PP or steel bands.
Disposal The drive contains raw materials that should be recycled to preserve energy and natural resources.
The package materials are environmentally compatible and recyclable. All metal parts can be recycled.
The plastic parts can either be recycled or burned under controlled circumstances, according to local
regulations. Most recyclable parts are marked with recycling marks.
If recycling is not feasible, all parts excluding electrolytic capacitors and printed circuit boards can be
landfilled. The DC capacitors (C1-1 to C1-x) contain electrolyte and the printed circuit boards contain
lead, both of which are classified as hazardous waste within the EU. They must be removed and
handled according to local regulations.
For further information on environmental aspects and more detailed recycling instructions, please
contact your local ABB distributor.
Applicable standards
See ACS800 Multidrive and Multidrive Modules Planning the Electrical Installation
CE marking
Compliance with the Machinery Directive

UL and CSA markings

Technical data
58
Technical data
59

This chapter contains example circuit diagrams of brake units. The example
diagrams help in understanding the internal connections and operation of the brake
unit.
WARNING! These example diagrams are not intended for wiring or diagnostic
purposes as they most probably differ from a customised brake unit. The customer
specific diagrams are attached to the delivery of a cabinet-installed unit.

60
R7i

61

62

63

64
R8i

65

66

67

68

69

70

71
R7i
72
73
74
R8i
Bottom cable exit and entry
75
76
77
Top cable exit and entry
78
79
80
Further information
Product and service inquiries
Address any inquiries about the product to your local ABB representative, quoting the type
designation and serial number of the unit in question. A listing of ABB sales, support and
service contacts can be found by navigating to www.abb.com/searchchannels.
Product training
For information on ABB product training, navigate to new.abb.com/service/training.
Providing feedback on ABB Drives manuals

Your comments on our manuals are welcome. Navigate to
new.abb.com/drives/manuals-feedback-form.
Document library on the Internet

You can find manuals and other product documents in PDF format on the Internet at
www.abb.com/drives/documents.
Contact us
www.abb.com/drives
www.abb.com/drivespartners
3AFE68925916 Rev C (EN) 2016-03-18

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ACS800

Drive hardware manuals and guides

Drive firmware manuals and guides

Option manuals and guides

 2016 ABB Oy. All Rights Reserved.

About this manual

Planning the installation

Generic guidelines for the electrical installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Example circuit diagrams

About this manual

What this chapter contains

About this manual

Essential information in other manuals

About this manual

Abbreviations and terms

Categorization by frame size

About this manual

Installation and commissioning flowchart

Check the ambient conditions, ratings, required coolant Technical data

Unpack and check the units. ACS800 Multidrive Mechanical Installation

Check the installation. Start-up, page 41

About this manual

What this chapter contains

Brake chopper control

Capacitor bank pre-charging

Main circuit diagram

DC+ and DC– fuses

ACS800-104 Brake module

Quick connector of brake

Resistor cabling (not

Brake resistors (not

Brake unit hardware

Layout drawing - bottom cable entry

1 Control panel (option +J400) and LED

6 Busbars for brake resistor cabling

8 Brake module fan

9 Control unit (RDCU) 1)

Layout drawing - top cable entry

1 Control panel (option +J400) and LED

5 Brake module fan

7 Busbars for brake resistor cabling

9 Control unit (RDCU, mounted on the

Brake module R7i

Front view with

2 Resistor (output) connection.

6 4 Power connection for cooling fan (X41).

5 Fibre optic connectors.

6 Prevention of unexpected start connector.

Brake module R8i

4 Retractable support legs

Power connections and control interfaces

Control unit (RDCU)

Control panel. Motor control and

Communication module 3: DDCS adapter (RDCO-0x)

PC, fieldbus AIMA

APBU Fibre optic link

Input power To motor

Supply Brake Brake Inverter

1) APBU is used only with parallel brake modules.

RMIO board connections

Type designation labels

4. Ratings of brake unit

5. Ratings of converter module when in inverter use