ABB ACS800-31 User manual

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ABB INDUSTRIAL DRIVES
ACS800-31 drives (5.5 to 110 kW)
ACS800-U31 drives (7.5 to 125 hp)
Hardware manual
ACS800_31.book Page 1 Friday, December 1, 2023 11:41 AM

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List of related manuals
You can find manuals and other product documents in PDF format on the Internet. See 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.
The code below opens an online listing of the manuals applicable to the product:
Drive hardware manuals and guides Code (English)
ACS800-31/U31 Drives Hardware Manual (5.5 to 110 kW, 7.5 to 125 hp) 3AFE68599954
Drive firmware manuals and guides
ACS800 Standard Control Program 7.x Firmware Manual and
Adaptive Program Application Guide
3AFE64527592
3AFE64527274
ACS800 IGBT Supply Control Program Firmware Manual 3AFE68315735
ACS800 System Control Program 7.x Firmware Manual and
Adaptive Program Application Guide
3AFE64670646
3AFE68420075
ACS800 Permanent Magnet Synchronous Machine Control Program Supplement to
Firmware Manual for System Control Program
3AFE64492641
ACS800 Permanent Magnet Synchronous Machine Drive Application Program
Supplement to Firmware Manual for ACS800 Standard Control Program 7.x
3AFE68437890
ACS800 Crane Control Program Firmware Manual 3AFE68775230
ACS800 Master/Follower Application Guide 3AFE64590430
ACS800 Pump Control Application Program 7.2 Firmware Manual 3AFE68478952
ACS800 Extruder Control Program Supplement 3AFE64648543
ACS800 Centrifuge Control Program Supplement 3AFE64667246
ACS800 Traverse Control Program Supplement 3AFE64618334
ACS800 Winch Control Program (+N698) Firmware Manual 3AUA0000031177
ACS800 Rod Pump Light Control Program Firmware Manual 3AUA0000005304
Option manuals and guides
ACS800-01/04/11/31/104/104LC Safe torque off function (+Q967), Application
guide 3AUA0000063373
RDCO-01/02/03 DDCS Communication Option Modules 3AFE64492209
AIMA-01 I/O Module Adapter User's Manual 3AFE64661442
NBRA-6xx Braking Choppers Installation and Start-up Guide 3AFY58920541
ACS800 Vibration Damper Installation Guide 3AFE68295351
Manuals and quick guides for I/O extension modules, fieldbus adapter, and so on.
ACS800-31/U31 manuals
ACS800_31.book Page 2 Friday, December 1, 2023 11:41 AM

ACS800-31 drives (5.5 to 110 kW)
ACS800-U31 drives (7.5 to 125 hp)
Hardware manual
3AFE68599954 Rev C
EN
EFFECTIVE: 2023-12-01
2023 ABB. All Rights Reserved.
1. Safety instructions
4. Mechanical installation
Table of contents
6. Electrical installation
11. Start-up and use
ACS800_31.book Page 3 Friday, December 1, 2023 11:41 AM

ACS800_31.book Page 4 Friday, December 1, 2023 11:41 AM

Table of contents 5
Table of contents
1. Table of contents
2. Safety instructions
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Use of warnings and notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Mechanical installation and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fiber-optic cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Permanent magnet motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installation and maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Start-up and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3. Introduction to this manual
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Categorization according to the frame size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Categorization according to the plus code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation and commissioning flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4. Operation principle and hardware description
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Product overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Line-side converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Motor-side converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
AC voltage and current waveforms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Printed circuit boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
DDCS communication modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Main circuit and control interfaces diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fieldbus control of the line-side converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Control block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Connection diagram of the RMIO board in the line-side converter . . . . . . . . . . . . . . . 32
Type code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5. Mechanical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Unpacking the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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6 Table of contents
Checking the delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Moving the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Before installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Requirements for the installation site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Free space around the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Mounting the drive on the wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Units without vibration dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Units with vibration dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Cabinet installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Preventing cooling air recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Unit above another . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Installing cabinet duct plates (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Installation kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Before you start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Assembly drawing for cabinet duct plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6. Planning the electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Motor selection and compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Protecting the motor insulation and bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Requirements table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Permanent magnet motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Supply connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Disconnecting device (disconnecting means) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
EU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
US . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Thermal overload and short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Thermal overload protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Protecting the motor against overload without the thermal model or temperature
sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Protecting the motor and motor cable in short circuits . . . . . . . . . . . . . . . . . . . . . . 54
Short-circuit protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Ground fault protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Emergency stop devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Prevention of unexpected start-up (option +Q950) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Safe torque off (option +Q967) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Safe torque off circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Selecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Alternative power cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Motor cable shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Additional US requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Armored cable / shielded power cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Power factor compensation capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Equipment connected to the motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Installation of safety switches, contactors, connection boxes, etc. . . . . . . . . . . . . 63
Bypass connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Using a contactor between the drive and the motor . . . . . . . . . . . . . . . . . . . . . . . . 64
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Table of contents 7
Protecting the relay output contacts and attenuating disturbances in case of induc-
tive loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Selecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Relay cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Control panel cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Connection of a motor temperature sensor to the drive I/O . . . . . . . . . . . . . . . . . . . . 67
Installation sites above 2000 m (6562 ft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Routing the cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Control cable ducts
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
7. Electrical installation
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Checking the insulation of the installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Supply cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Motor and motor cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
IT (ungrounded) systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Disconnecting the EMC filter capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Units of frame size R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Units of frame size R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Connecting the power cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Conductor stripping lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Allowed wire sizes, tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Wall installed units (European version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Power cable installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Wall installed units (US version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Warning sticker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Cabinet installed units (IP00, UL type open) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Connecting the control cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
360-degree grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Connecting the shield wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Cabling of I/O and fieldbus modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Pulse encoder module cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Attaching the control cables and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Installation of optional modules and PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Connecting a PC to the motor-side RMIO board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
8. Installation of the AGPS board (Prevention of unexpected start-up, +Q950)
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Prevention of unexpected start-up (+Q950) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Installation of the AGPS board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Start-up and validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Dimensional drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
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8 Table of contents
9. Installation of the ASTO board (Safe torque off, +Q967)
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Safe torque off (+Q967) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Installation of the ASTO board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Validation and start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Dimensional drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
10. Motor control and I/O board (RMIO)
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Note on terminal labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Note on external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
External control connections (non-US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
External control connections (US) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
RMIO board specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Analogue inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Constant voltage output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Auxiliary power output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Analogue outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Digital inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Relay outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
DDCS fiber-optic link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
24 VDC power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
11. Installation checklist
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Installation checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
12. Start-up and use
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Start-up and use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
To control the line-side converter... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
To control the motor-side converter... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Removing the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
13. Actual signals and parameters
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Line-side converter actual signals and parameters in the motor-side converter con-
trol program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Actual signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
09 ACTUAL SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
95 HARDWARE SPECIF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
ACS800-31/U31 specific parameters in the IGBT Supply Control Program . . . . . . 109
Terms and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
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Table of contents 9
16 SYSTEM CTR INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
31 AUTOMATIC RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Fixed parameters with the ACS800-31 and ACS800-U31 . . . . . . . . . . . . . . . . . . . . . 111
14. Maintenance
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Heatsink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Main cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Fan replacement (R5, R6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Additional fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Replacement (R5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Replacement (R6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Reforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
15. Fault tracing
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Faults and warnings displayed by the CDP 312R control panel . . . . . . . . . . . . . . . . . . 117
Conflicting ID numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
16. Technical data
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
IEC data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Temperature derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Altitude derating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Mains cable fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Cable entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Dimensions, weights and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
NEMA data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Input cable fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Cable types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Cable Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Dimensions, weights and noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Input power connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Motor connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Degree of protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
AGPS-11C (option +Q950) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
ASTO-11C (option +Q967) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
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10 Table of contents
Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Applicable standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
CE marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Compliance with the European Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . 132
Compliance with the European EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Compliance with the European Machinery Directive . . . . . . . . . . . . . . . . . . . . . . . . . 132
Compliance with EN 61800-3:2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
First environment (drive of category C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Second environment (drive of category C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Second environment (drive of category C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
“C-tick” marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
UL/CSA markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
UL checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
17. Dimensional drawings
Frame size R5 (IP21, UL type open, UL type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Frame size R6 (IP21, UL type open, UL type 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Cabinet duct plates (optional), frame size R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Cabinet duct plates (optional), frame size R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Package (frame size R5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Package (frame size R6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
AGPS board with enclosure (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
ASTO board with enclosure (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
18. Resistor braking
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
How to select the correct drive/chopper/resistor combination . . . . . . . . . . . . . . . . 145
External brake chopper and resistor(s) for the ACS800-31/U31 . . . . . . . . . . . . . . . . 146
Brake chopper and resistor installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Brake circuit commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
19. External +24 V power supply for the RMIO boards via terminal X34
What this chapter contains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Parameter settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Connecting 24 V external power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
RMIO board of the motor-side converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
RMIO board of the line-side converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Frame size R5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Frame size R6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Further information
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Safety instructions 11
1
Safety instructions
What this chapter contains
This chapter contains the safety instructions that you must obey when you install,
operate and service the drive. If you ignore them, physical injury or death may occur,
or damage may occur to the drive, motor or driven equipment.
Read the safety instructions before you do work on the unit.
Use of warnings and notes
Warnings tell you about conditions that can cause serious injury or death or damage
to the equipment. They also tell you how to avoid the danger.
Notes tell you about particular conditions or facts, or give additional information.
The warning symbols in this document:
Dangerous voltage warning warns of high voltage which can cause
physical injury and/or damage to the equipment.
General warning warns about conditions, other than those caused
by electricity, which can result in physical injury and/or damage to
the equipment.
Electrostatic discharge warning warns of electrostatic discharge
which can damage the equipment.
Hot surface warning warns of hot surfaces which can cause physical
injury.
ACS800_31.book Page 11 Friday, December 1, 2023 11:41 AM

12 Safety instructions
Installation and maintenance work
These warnings are intended for all person that do work on the drive, motor cable or
motor.
WARNING! If you ignore these safety instructions, physical injury or death,
or damage to the equipment can occur:
•Only qualified electricians are allowed to install and maintain the drive.
•Do not do work on the drive, motor cable or motor when input power is
connected. After you disconnect the input power, wait for 5 minutes to let
the intermediate circuit capacitors discharge before you do work on the
drive, motor or motor cable.
Use a multimeter with a minimum impedance of 1 Mohm to measure that:
1. The voltage between input phases U1, V1 and W1 and the frame is close
to 0 V.
2. The voltage between terminals UDC+ and UDC- and the frame is close to
0V.
•Do not do work on the control cables when the power is applied to the drive
or to the external control circuits. Externally-supplied control circuits can
cause dangerous voltages inside the drive even when the main power of the
drive is off.
•Do not do insulation or voltage withstand tests on the drive or drive
modules.
•When you connect the motor cable, make sure that the phase order is
correct.
•After you maintain or modify a drive safety circuit, or change circuit boards
in the module, test the operation of the safety circuit according to the start-
up instructions.
•Do not change the electrical installation of the drive except for the essential
control and power connections. Such changes can affect the safety or
operation of the drive. All customer-made changes are the responsibility of
the customer.
Notes
•The motor cable terminals on the drive are at a dangerously high voltage
when the input power is on, regardless of whether the motor operates.
•The brake control terminals (UDC+, UDC-, R+ and R- terminals) have a
dangerous DC voltage (over 500 V).
•Depending on the external wiring, dangerous voltages (115 V, 220 V or
230 V) can be present on the terminals of relay outputs RO1 to RO3 or on the
optional AGPS board (Prevention of unexpected start-up).
•The Prevention of unexpected start-up function (option +Q950) does not
remove the voltage from the main circuit or auxiliary circuits.
ACS800_31.book Page 12 Friday, December 1, 2023 11:41 AM

Safety instructions 13
Grounding
These instructions are intended for all persons that are responsible for the
grounding of the drive.
•The Safe torque off function (option +Q967) does not remove the voltage
from the main circuit or auxiliary circuits.
•At installation sites that are above 2000 m (6562 ft), the terminals of the
RMIO board and option modules attached to the board do not fulfill the
Protective Extra Low Voltage (PELV) requirements in EN 50178 and
EN 61800-5-1.
WARNING! If you ignore these instructions, it can cause physical injury,
death, increased electromagnetic interference and equipment
malfunction:
•Ground the drive, motor and adjoining equipment to ensure personnel
safety in all circumstances, and to reduce electromagnetic emission and
interference.
•Make sure that the grounding conductors are adequately sized as required
by the safety regulations.
•In a multiple-drive installation, connect each drive separately to the
protective earth (PE).
•In European CE compliant installations and in other installations where EMC
emissions must be minimized, make a 360° high-frequency grounding of
the cable entries in order to suppress electromagnetic disturbances.
In addition, connect the cable shields to the protective earth (PE) in order to
meet safety regulations.
•Do not install a drive with EMC filter option +E202 or +E200 on an
ungrounded power system or a high-resistance-grounded (more than
30 ohms) power system. Before you connect the drive to the power system,
disconnect the EMC filter capacitors as described in IT (ungrounded)
systems on page 70.
Notes
•Power cable shields are suitable for equipment grounding conductors only
when adequately sized to meet safety regulations.
•As the normal leakage current of the drive is more than 3.5 mA AC or
10 mA DC (EN 61800-5-1, 4.3.5.5.2), a fixed protective earth connection is
required.
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14 Safety instructions
Mechanical installation and maintenance
These instructions are intended for all persons that install and service the drive.
Printed circuit boards
Fiber-optic cables
WARNING! If you ignore these instructions, physical injury or death, or
damage to the equipment can occur:
•Handle the unit carefully.
•The drive is heavy. Do not lift it alone. Do not lift the unit by the front cover.
Place the unit only on its back.
•Beware of hot surfaces. Some parts, such as heat sinks, are hot for a while
after disconnection.
•Make sure that dust from drilling, boring and grinding does not go into the
drive. Electrically conductive dust inside the unit can cause damage or
faults.
•Make sure that cooling is sufficient.
•Do not fasten the drive by riveting or welding.
WARNING! If you ignore these instructions, damage to the printed circuit
boards can occur.
The printed circuit boards have components that are sensitive to
electrostatic discharge. Use an ESD wrist band when you touch the
printed circuit boards. Do not touch them unnecessarily.
WARNING! If you ignore these instructions, it can cause equipment
malfunction and damage to the fiber-optic cables:
Handle the fiber-optic cables with care. When you disconnect fiber-optic
cables, always hold the connector, not the cable. Do not touch the ends of
the fibers with bare hands as the fiber is extremely sensitive to dirt. The
minimum allowed bend radius is 35 mm (1.4 in.).
Do not tilt!
ACS800_31.book Page 14 Friday, December 1, 2023 11:41 AM

Safety instructions 15
Operation
These warnings are intended for all persons that plan the operation of the drive or
operate the drive.
WARNING! If you ignore these instructions, physical injury or death, or
damage to the equipment can occur:
Before you adjust the drive and put it into service, make sure that the
motor and all of the driven equipment are suitable for operation
throughout the speed range provided by the drive. The drive can be
adjusted to operate the motor at speeds above and below the speed
provided by connecting the motor directly to the power line.
Before you activate the automatic fault reset or automatic restart
functions of the drive control program, make sure that no dangerous
situations can occur. These functions reset the drive automatically and
continue operation after a fault or supply break. If these functions are
activated, the installation must be clearly marked as defined in IEC/EN
61800-5-1, subclause 6.5.3, for example, "THIS MACHINE STARTS
AUTOMATICALLY".
Do not control the motor with the disconnecting device. Use the control
panel keys and , or commands through the I/O board of the drive.
The maximum allowed number of charging cycles of the DC capacitors
(that is, power-ups by applying power) is five in ten minutes.
The Safe torque off function (option +Q967) can be used for stopping the
drive in emergency stop situations. In the normal operating mode, use the
Stop command instead.
Notes
If an external source for the start command is selected and it is ON, the
drive (with the Standard Control Program) starts immediately after a fault
reset unless the drive is configured for 3-wire (a pulse) start/stop.
When the control location is not set to Local (L not shown in the status
row of the display), the Stop key on the control panel does not stop the
drive. To stop the drive using the control panel, press the LOC/REM key
and then the Stop key .
ACS800_31.book Page 15 Friday, December 1, 2023 11:41 AM

16 Safety instructions
Permanent magnet motor
These are additional warnings for permanent magnet motor drives. If you ignore the
instructions, physical injury or death, or damage to the equipment can occur.
Control a permanent magnet motor only with the ACS800 Permanent Magnet
Synchronous Motor Drive Control Program.
Installation and maintenance work
WARNING! Do not do work on the drive when the permanent magnet motor
turns. When the supply power is off and the inverter is stopped, a turning
permanent magnet motor feeds power to the intermediate circuit of the
drive and the supply connections become live.
Before you do installation and maintenance work on the drive:
•Stop the motor.
•Make sure that the motor cannot turn during work. Prevent the start-up of any
drives in the same group by opening the Prevention of unexpected start switch
(option +Q950) or the Safe torque off switch (option +Q967) and locking it. Make
sure that no other system, such as hydraulic crawling drives, are able to turn the
motor directly or through any mechanical connection such as felt, nip, rope, and
so on.
•Make sure that there is no voltage on the drive power terminals:
Alternative 1) Disconnect the motor from the drive with a safety switch or by
other means. Measure that there is no voltage present on the drive input, output
or DC terminals (U1, V1, W1, U2, V2, W2, UDC+, UDC-).
Alternative 2) Measure that there is no voltage present on the drive input, output
or DC terminals (U1, V1, W1, U2, V2, W2, UDC+, UDC-). Ground the drive output
terminals temporarily by connecting them together and to the PE.
Alternative 3) If it is possible, do both of the above .
Start-up and operation
WARNING! Do not run the motor over the rated speed. Motor overspeed
leads to overvoltage which can damage the capacitors in the intermediate
circuit of the drive.
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Introduction to this manual 17
2
Introduction to this manual
What this chapter contains
This chapter describes the intended audience and contents of this manual. It has a
flowchart of steps to check the delivery, install and commission the drive. The
flowchart refers to parts in this manual and other manuals.
Intended audience
This manual is intended for persons who plan the installation, install, commission,
use and service the drive. Read this manual before you do work on the drive. The
reader is expected to know the fundamentals of electricity, wiring, electrical
components and electrical schematic symbols.
This manual is written for a global audience. Both SI and imperial units are shown.
Special US instructions for installations within the United States that must be
installed per the National Electrical Code and local codes are marked with (US).
Categorization according to the frame size
Some instructions, technical data and dimensional drawings that concern specific
frame sizes are marked with the symbol of the frame size R2, R3... or R8. The frame
size is not marked on the drive designation label. To identify the frame size of your
drive, see the rating tables in
Technical data (page 119).
The ACS800-31/U31 is manufactured in frame sizes R5 and R6.
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18 Introduction to this manual
Categorization according to the plus code
The instructions, technical data and dimensional drawings that concern specific
optional selections are marked with + codes, for example, +E202. You can identify
the options in the drive from the + codes on the type designation label. The + code
selections are listed in
Type code (page 33).
Contents
The chapters of this manual are briefly described below.
Safety instructions (page 11) give safety instructions for the installation,
commissioning, operation and maintenance of the drive.
Introduction to this manual (page 17) lists the steps in checking the delivery and
installing and commissioning the drive and refers to parts in this manual and other
manuals for particular tasks.
Operation principle and hardware description (page 23) describes the drive.
Mechanical installation (page 35) instructs in how to place and mount the drive.
Planning the electrical installation (page 45) instructs in the motor and cable
selection, protections and cable routing.
Electrical installation (page 69) shows how to wire the drive.
Installation of the AGPS board (Prevention of unexpected start-up, +Q950) (page 83)
describes the electrical installation of the optional Prevention of unexpected start-
up function (+Q950).
Installation of the ASTO board (Safe torque off, +Q967) (page 87) describes the
electrical installation of the optional Safe torque off function (+Q967).
Motor control and I/O board (RMIO) (page 91) shows the external control
connections to the I/O board.
Installation checklist (page 99) contains a list for checking the mechanical and
electrical installation of the drive.
Start-up and use (page 103) describes the start-up procedure and use of the drive.
Actual signals and parameters (page 107) contains listings of parameters specific to
the ACS800-31 and ACS800-U31.
Maintenance (page 113) contains preventive maintenance instructions.
Fault tracing (page 117) contains guidelines for fault tracing.
Technical data (page 119) contains the technical specifications of the drive, for
example, the ratings, sizes and technical requirements and provisions for fulfilling
the requirements for CE and other markings.
Dimensional drawings (page 137) contains the dimensional drawings of the drive.
Resistor braking (page 145) describes how to select, protect and wire external brake
choppers and resistors for the drive. The chapter also contains installation
instructions and the technical data.
External +24 V power supply for the RMIO boards via terminal X34 (page 149)
describes how to connect an external +24 V power supply for the RMIO board using
terminal X34.
ACS800_31.book Page 18 Friday, December 1, 2023 11:41 AM

Introduction to this manual 19
Installation and commissioning flowchart
Task See
Identify the frame size of your drive: R5 or R6. IEC data (page 119) or NEMA data (page 125)
Plan the installation.
Check the ambient conditions, ratings, required
cooling air flow, input power connection,
compatibility of the motor, motor connection,
and other technical data.
Select the cables.
Technical data (page 119)
Planning the electrical installation (page 45)
For compliance with the European Union EMC
Directive, see CE marking (page 132)
Option manual (if optional equipment is included)
Unpack and check the units.
Check that all necessary optional modules and
equipment are present and correct.
Only intact units may be started up.
Unpacking the unit (page 35)
If the converter was non-operational for more
than one year, the converter DC link capacitors
need to be reformed, see Capacitors (page 116).
If the drive is about to be connected to an IT
(ungrounded) system, make sure that the drive is
does not have EMC filtering intended for
grounded systems, or disconnect the EMC filter
capacitors.
Type code (page 33)
IT (ungrounded) systems (page 70)
Check the installation site. Before installation (page 38)
Technical data (page 119)
Install the drive on a wall or in a cabinet. Mechanical installation (page 35)
Route the cables. Routing the cables (page 67)
For compliance with the European Union EMC
Directive, see CE marking (page 132)
ACS800_31.book Page 19 Friday, December 1, 2023 11:41 AM

20 Introduction to this manual
Check the insulation of the motor and the motor
cable.
Checking the insulation of the installation
(page 69)
Connect the power cables.
Connect the motor cable.
Electrical installation (page 69)
Connect the control and auxiliary control cables. Electrical installation (page 69), Motor control and
I/O board (RMIO) (page 91), Installation of the
AGPS board (Prevention of unexpected start-up,
+Q950) (page 83), Installation of the ASTO board
(Safe torque off, +Q967) (page 87) and the
optional module manual delivered with the
module.
Check the installation. Installation checklist (page 99)
Commission the drive. Start-up and use (page 103), appropriate control
program firmware manual
Task See
ACS800_31.book Page 20 Friday, December 1, 2023 11:41 AM