ACS800-04 and ACS800-04M Drive Modules (45 to 560 kW)

• input bridge protection board (AIBP) which includes snubbers for the thyristors and varistors

• power supply board (APOW)

• gate driver control board (AGDR) 

• diagnostics and panel interface board (ADPI)

• brake chopper control board (ABRC) with option +D150Motor control

The motor control is based on the Direct Torque Control (DTC) method. Two phase currents and DC link voltage are measured and used for the control. The third phase current is measured for earth fault protection.

What this chapter contains

This chapter describes the mechanical installation of the drive cabinet generally. 

Follow the specific instructions given by the panel builder. For the mechanical assembly and dimensional drawings of the drive module, refer to ACS800-04/04M/U4 Cabinet Installation [3AFE68360323 (English)] and ACS800-04/04M/U4 Drive Modules (45 to 560 kW, 60 to 600 hp) Rittal TS 8 Cabinet Installation[3AFE68372330 (English)].

Unpacking the unit

The drive delivery contains:

• drive module including factory installed options such as optional modules (inserted onto the RMIO board in the RDCU control unit)

• residual voltage warning stickers

• hardware manual

• appropriate firmware manuals and guides

• appropriate optional module manuals

• delivery documents.

Note: Do not discard any important components that are in separate cardboard boxes, for example, under the drive module.

Fastening the cabinet to the floor and wall

Fasten the cabinet to the floor and wall/roof according to the panel builder’s instructions, e.g. with outside fastening brackets or by fastening holes inside the cabinet. 

Electric welding

It is not recommended to fasten the cabinet by welding.

If the preferred fastening methods (clamping or bolting through the holes inside the cabinet) cannot be used, proceed as follows:

• Connect the return conductor of the welding equipment to the cabinet frame at the bottom within 0.5 metres of the welding point.

Motor selection and compatibility

1. Select the motor according to the rating tables in chapter Technical data. Use the DriveSize PC tool if the default load cycles are not applicable.

2. Check that the motor ratings lie within the allowed ranges of the drive control program: 

• motor nominal voltage is 1/2 ... 2 · UN of the drive

• motor nominal current is 1/6 ... 2 · I2hd of the drive in DTC control and 0 ... 2 · I2hd in scalar control. The control mode is selected by a drive parameter.

3.UN = rated input voltage of the drive

UACeq1 = UDC/1.35

UACeq1 = the equivalent AC power source voltage of the drive in V AC.

UDC = the maximum DC link voltage of the drive in V DC.

For resistor braking: UDC= 1.21 × nominal DC link voltage.

Note: Nominal DC link voltage is UN × 1.35 in V DC.

See note 7 below the Requirements table, page 42.

4. Consult the motor manufacturer before using a motor in a drive system where the motor nominal voltage differs from the AC power source voltage.

5. Ensure that the motor insulation system withstands the maximum peak voltage in the motor terminals. See the Requirements table below for the required motor insulation system and drive filtering.

When the supply voltage is 440 V and a drive with a diode supply is operating in motor mode only, the maximum peak voltage in the motor terminals can be approximated as follows: 440 V · 1.35 · 2 = 1190 V. Check that the motor insulation system withstands this voltage.