ABB 68606039 ACS800-104LC-0700-7 560 kW Liquid - Cooled Inverter Module

Product Overview: ABB 68606039 ACS800-104LC-0700-7

The ABB ACS800-104LC series represents the liquid-cooled inverter module lineup within ABB's ACS800 multidrive system. While the ACS800-704LC drive supply unit converts AC mains to DC bus power, the ACS800-104LC inverter module performs the inverse transformation-converting the shared DC bus voltage into variable-frequency, variable-voltage AC power to control large induction or synchronous motors.

This particular module - type code 0700-7 - is rated for 700 Adc input from the DC bus and delivers 583 A continuous output current at the motor terminals, corresponding to a maximum motor power of 560 kW (≈ 750 HP) when operating at 690 VAC. The "-7" suffix indicates the 690V voltage class, compatible with standard low-voltage industrial motors in the 500–690 V range per IEC 60034.

The inclusion of the +E205 du/dt filter is a significant value-add. In modern PWM inverter drives, the rapid switching of IGBT transistors (typical rise times < 100 ns) creates voltage spikes at the motor terminals that can reach 2–3× the nominal DC bus voltage. These high du/dt transients stress motor winding insulation, accelerate bearing currents, and can cause premature motor failure - especially in motors with long cable runs (> 50 meters) or older insulation systems. The +E205 filter limits the voltage rise rate to safe levels, extending motor life and reducing maintenance costs.

Equally important is the +Q950 AGPS-21C safety option, which implements ABB's Safe Torque Off (STO) function compliant with IEC 61800-5-2 and ISO 13849-1 Category 3 / PL e. When a safety command is triggered (via safety PLC or emergency stop circuit), the AGPS-21C board immediately disables the IGBT gate drivers, removing torque from the motor within milliseconds. This is essential for applications requiring SIL 2 or SIL 3 safety integrity levels, such as steel mill machinery, cranes, and chemical processing equipment.

Technical Specifications

Key Features & Benefits

• 560 kW Output Power: Drives large industrial motors up to 750 HP with precise speed and torque control, supporting the most demanding constant-torque and variable-torque applications.
• +E205 du/dt Filter (Factory-Installed): Protects motor winding insulation from destructive voltage spikes caused by fast IGBT switching. Essential for motors with long cable runs (>50m), aged insulation, or operation in critical processes where motor failure is unacceptable.
• +Q950 AGPS-21C Safe Torque Off: Integrated STO safety function achieves Category 3 / PL e per ISO 13849-1 and SIL 2 per IEC 61508. The AGPS-21C board independently monitors safety relays and force-disables IGBT gates within < 1 ms of safety command—eliminating the need for external contactor-based safety circuits.
• Liquid-Cooled Design: Closed-loop coolant system enables full 560 kW output in ambient temperatures up to 55°C without derating. Ideal for steel mills, marine engine rooms, and tropical climates where air-cooled drives would require oversized HVAC systems.
• Wide DC Bus Voltage Range (709–976 VDC): Compatible with all standard ACS800 drive supply units including the ACS800-704LC-2150-7 DSU, allowing flexible system design across 380V, 480V, 500V, and 690V AC supply networks.
• 0–300 Hz Frequency Range: Supports both standard 50/60 Hz motors and high-speed applications such as spindle drives, test rigs, and special-purpose machinery requiring extended speed ranges.
• Direct Torque Control (DTC): ABB's patented DTC algorithm delivers motor control accuracy of ±0.01% speed and ±0.1% torque without requiring shaft encoders in most applications—reducing system complexity and maintenance.
• Modular Multidrive Architecture: Designed for installation in common DC bus systems where multiple inverter modules share a single drive supply unit. Reduces component count, wiring complexity, and overall system footprint compared to standalone drive configurations.
• Proven Industrial Reliability: The ACS800 platform has accumulated billions of operating hours across heavy industry worldwide. Buying a tested used unit from Aeliya Marine Tech gives you this proven reliability at a fraction of new cost.

Industrial Applications for the ABB ACS800-104LC-0700-7

Steel & Metals Rolling Mills

Hot and cold rolling mills require precise torque and tension control across multiple drive stands. A single ACS800-104LC-0700-7 can power a main mill stand motor of 500–750 HP, while the AGPS-21C safety circuit ensures immediate torque removal during cobble events or operator emergency stops—preventing equipment damage and personnel injury. The du/dt filter is particularly valuable here, as mill motors often operate with long power cables and experience severe mechanical and thermal stress.

Marine Propulsion & Deck Machinery

Electric propulsion motors on offshore vessels, tugs, and ferries typically fall within the 400–800 kW range per azimuth thruster—well within this inverter's capability. The liquid-cooled design operates reliably in the high-temperature, salt-air environment of marine engine rooms. The AGPS-21C STO function integrates with vessel-wide safety management systems (SMS) for compliance with IACS and classification society requirements. ABB's marine-certified ACS800 drives are approved by DNV, Lloyd's Register, Bureau Veritas, and ABS.

Large-Scale Material Handling & Mining

Overland conveyors, bucket wheel reclaimers, and stacker-reclaimers in mining and port operations use 500+ HP motors for bulk material transport. The DTC control algorithm provides precise starting torque control (critical for loaded conveyor restart) and regenerative braking for downhill sections. The modular multidrive approach allows a single drive supply unit to feed multiple 560 kW inverter modules along a multi-kilometer conveyor route.

Water & Wastewater Pumping Stations

Large raw water intake pumps, sewage lift station pumps, and desalination high-pressure pumps in the 400–600 kW range benefit from the precise flow control and energy savings provided by VFD operation. The du/dt filter extends motor insulation life in these 24/7 critical infrastructure applications where unplanned downtime carries severe regulatory and public health consequences.

Test Rigs & Industrial Research

Automotive and aerospace test facilities use high-power inverter drives for dynamometer systems, engine test cells, and structural fatigue testing. The 0–300 Hz output range supports high-speed testing requirements, while DTC's ±0.01% speed accuracy ensures repeatable test conditions.

Why Buy From Aeliya Marine Tech?

Installation & Commissioning Guide

Proper installation of the ABB 68606039 ACS800-104LC-0700-7 requires adherence to ABB's installation guidelines and relevant electrical safety codes. Below is a summary of the key steps. For complete details, refer to the ACS800 Multidrive Hardware Manual.

Step 1: Mechanical Installation

The 127 kg module mounts in an ACS800 multidrive cabinet on slide rails for service access. Install with the heatsink (cooling plate) facing the cabinet rear panel where coolant connections are made. Maintain minimum 100 mm side clearance to adjacent modules for air gap insulation. Torque all chassis ground connections to 10 Nm.

Step 2: Coolant Circuit Connection

Connect the liquid cooling circuit using the two G1-inch BSP ports on the module rear. Use stainless steel braided hoses rated for 10 bar working pressure. Recommended coolant: 40% propylene glycol / 60% deionized water with corrosion inhibitor (pH 8.0–9.5). Minimum flow rate: 12 L/min. Maximum inlet temperature: 45°C. Install a manual bleed valve at the highest point to purge air from the circuit.

Step 3: DC Bus Connection

Connect the DC+ and DC– bus bars from the drive supply unit (or common DC bus) to the module's input terminals. Use copper bus bars sized for 700 A continuous current (minimum 30 × 10 mm cross-section). Apply NOALOX or equivalent antioxidant compound to aluminum bus bar joints. Torque M10 DC terminals to 35–40 Nm.

Step 4: Motor Output Wiring (with du/dt Filter)

The +E205 du/dt filter is integrated within the module—no external filter installation is required. Connect the three motor phases (U, V, W) using shielded symmetrical motor cable (e.g., EMC 4G240) with the shield grounded at both inverter and motor ends. Maximum recommended cable length with integrated filter: 150 meters. Torque M10 output terminals to 35–40 Nm.

Step 5: AGPS-21C Safety Circuit Wiring

The +Q950 AGPS-21C board occupies slot 4 of the RMIO control unit. Connect the safe torque off inputs (AGPS terminals X1:1–4) to your safety PLC or safety relay outputs using twin-safe or equivalent safety-rated cabling. Verify STO response time < 1 ms using a safety tester. Connect the AGPS diagnostic output to your PLC digital input for status monitoring.

Step 6: Control & Communication

Connect the DriveBus cable between the inverter module and the BCU control unit. Configure the module address (parameter 51.01), motor nominal values (parameters 99.05–99.09), and application macros (parameter 99.02). For DTC mode, enter motor nameplate data and run the ID Run (parameter 99.10) for automatic motor model identification.

Step 7: Commissioning & Testing

Perform the following verification sequence: (1) Insulation resistance test at 1000V DC (> 1 MΩ minimum), (2) Coolant flow verification, (3) No-load run at 25/50/75/100% speed, (4) Loaded run at 50% torque for 30 minutes, (5) Full-load run at 100% torque for 2 hours with thermal imaging, (6) STO safety function test with torque verification.

Safety Warning: Installation must be performed by qualified electricians only. The DC bus capacitors retain lethal voltages for up to 5 minutes after power disconnection. Always verify zero voltage with a calibrated meter before touching any terminals. Follow lockout/tagout procedures per OSHA 1910.147.

Frequently Asked Questions (FAQ)

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External Technical Resources

• ABB ACS800 Multidrive Catalog (PDF) – Complete product catalog with dimensional data, selection tables, and option codes.
• ABB Drives Official Website – Product updates, software downloads (Drive Window, Drive Composer), and application stories.
• ABB ACS800 Technical Reference – Detailed technical documentation and application notes for the ACS800 platform.
• IEC 61800-5-2 – Adjustable speed electrical power drive systems – Safety requirements – Functional safety.
• ISO 13849-1:2023 – Safety of machinery – Safety-related parts of control systems.