Page 1 — ABB INDUSTRIAL DRIVES ACS880-04 drive modules (200 to 710 kW, 250 to 700 hp) Hardware manual...
Page 3 ACS880-04 drive modules (200 to 710 kW, 250 to 700 hp) Hardware manual Table of contents 1. Safety instructions 6. Mechanical installation 8. Electrical installation 13. Start-up 3AUA0000128301 Rev J EFFECTIVE: 2020-10-26...
Page 5: Table Of Contents
Table of contents 5 Table of contents 1 Safety instructions Contents of this chapter ..................Use of warnings and notes ................. General safety in installation, start-up and maintenance ........Electrical safety in installation, start-up and maintenance ........Electrical safety precautions ................ Additional instructions and notes ..............
Page 6 6 Table of contents Overview of power and control connections ............Type designation label ..................Type designation key ..................Basic code ....................Option codes ....................4 Generic cabinet planning instructions Contents of this chapter ..................Limitation of liability ..................... Cabinet construction ................... Disposition of the devices ................
Page 7 Table of contents 7 Free space around the drive module ............Other installation positions than vertical ............. Placement of the control panel ................ABB air inlet and outlet kits ................. 6 Mechanical installation Contents of this chapter ..................Safety ........................
Page 8 Availability of du/dt filter and common mode filter by drive type ..Additional requirements for explosion-safe (EX) motors ....Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and AM_ ..............Additional requirements for ABB high-output and IP23 motors ..
Page 9 Table of contents 9 Implementing a motor temperature sensor connection ........Connecting motor temperature sensor to the drive via an option module ..Implementing the emergency stop function ............Implementing the Safe torque off function ............Implementing the functions provided by the FSO-xx safety functions module ..Using power factor compensation capacitors with the drive .......
Page 10 Connecting the power cables and installing the shrouds ........Installing the roof and door (Rittal parts) ............. Installing the roof and door (ABB air filters and roof) .......... Removing the protective covering from the drive module air outlet ....Miscellaneous .....................
Page 11 Table of contents 11 Required parts ....................Required tools ..................... Overall flowchart of the installation process ............Installing the mechanical accessories into the enclosure ........Connecting the power cables ................Power cable connection diagram ..............Power cable connection procedure .............. Installing the drive module into the enclosure .............
Page 12 12 Table of contents Fans ........................Replacing the circuit board compartment cooling fans ........ Replacing the main cooling fans ..............Replacing the standard drive module ..............Replacing the drive module with option +H381 ..........Capacitors ......................Reforming the capacitors ................Control panel .......................
Page 13 Table of contents 13 Losses, cooling data and noise ................Typical power cable sizes ................... Terminal and entry data for the power cables ............. Units with optional cabling panels (+H381) ..........Units without full-size output cable connection terminals (+0H371) and with a common mode filter (+E208) ..............
Page 14 14 Table of contents R11 with options +E208+H356+H381+J414+P905 ..........R11 with options +0B051+C173+E208+H356+0H354+0H371 ......R11 – Cabling panels (+H381) installed into a Rittal VX25 enclosure ....Bottom plate for option +H381 in Rittal VX25 400 mm wide enclosure installation ......................Frame R11 with options +E208+H370+H391+0J400 .........
Page 15 Table of contents 15 21 Resistor braking Contents of this chapter ..................When is resistor braking necessary? ..............Operation principle and hardware description ............ Planning the braking system ................Generic guidelines ..................Resistor cables ................. Resistor thermal switch ..............Protecting the system against thermal overload ....... EMC compliance of the complete installation ........
Page 16 16 Table of contents 23 Step-by-step drawings for an installation example of standard drive configuration with option +E208 in Rittal VX25 600 mm wide enclosure 24 Step-by-step drawings for installing full cabling panels (option +H381) in a Rittal 400 mm wide enclosure Installation procedure .
Page 17: Safety Instructions
Safety instructions 17 Safety instructions Contents of this chapter This chapter contains the safety instructions which you must obey when you install, start up, operate and do maintenance work on the drive. If you ignore the safety instructions, injury, death or damage can occur. Use of warnings and notes Warnings tell you about conditions which can cause injury or death, or damage to the equipment.
Page 18: General Safety In Installation, Start-Up And Maintenance
18 Safety instructions General safety in installation, start-up and maintenance These instructions are for all personnel who do work on the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. •...
Page 19 Safety instructions 19 3AUA0000086323 • To prevent the drive module from falling, attach its top lifting lugs with chains to the cabinet (1) before you push the module into the cabinet and pull it from the cabinet. Push the module into the cabinet and pull it from the cabinet carefully preferably with help from another person.
Page 20: Electrical Safety In Installation, Start-Up And Maintenance
20 Safety instructions • Vacuum clean the area around the drive before the start-up to prevent the drive cooling fan from drawing the dust inside the drive. • Make sure that debris from drilling, cutting and grinding does not enter the drive during the installation.
Page 21 Safety instructions 21 WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. Go through these steps before you begin any installation or maintenance work. 1.
Page 22: Additional Instructions And Notes
22 Safety instructions 6. Install temporary grounding as required by the local regulations. 7. Ask the person in control of the electrical installation work for a permit to work. ￭ Additional instructions and notes WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.
Page 23: Optical Components
Safety instructions 23 Optical components WARNING! Obey these instructions. If you ignore them, damage to the equipment can occur. • Handle the fiber optic cables with care. • When you unplug the fiber optic cables, always hold the connector, not the cable itself.
Page 24: General Safety In Operation
24 Safety instructions Note: • You can use power cable shields as grounding conductors only when their conductivity is sufficient. • As the normal touch current of the drive is higher than 3.5 mA AC or 10 mA DC, you must use a fixed protective earth (PE) connection.
Page 25: Additional Instructions For Permanent Magnet Motor Drives
Safety instructions 25 Additional instructions for permanent magnet motor drives ￭ Safety in installation, start-up, maintenance These are additional warnings concerning permanent magnet motor drives. The other safety instructions in this chapter are also valid. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur.
Page 27: Introduction To The Manual
The flowchart refers to chapters/sections in this manual and other manuals. Applicability This manual applies to ACS880-04 drive modules intended for user-defined cabinet installations. Target audience This manual is intended for people who plan the installation, install, start up and do maintenance work on the drive, or create instructions for the end user of the drive concerning the installation and maintenance of the drive.
Page 28: Categorization By Frame Size And Option Code
28 Introduction to the manual Categorization by frame size and option code The instructions, technical data and dimension drawings which concern only certain drive frame sizes are marked with the symbol of the frame size (R10 or R11). The frame size is marked on the type designation label.
Page 29 Introduction to the manual 29 Task Standard drive modules Mechanical installation (page 79) • Install the additional components into the Connecting the power cables (page 126) cabinet: eg, main disconnector, main contact- Connecting the external control unit to the drive or, main AC fuses, etc.
Page 30: Terms And Abbreviations
30 Introduction to the manual Task Drive modules without full-size output cable Mechanical installation (page 79) connection terminals (option +0H371) and IP20 Connecting the power cables (page 126) shrouds (option +0B051) Installing the drive module into the enclos- • Install the additional components into the ure (page 172) cabinet: eg, main PE busbar, main disconnect- Connecting the external control unit to the drive...
Page 31 Introduction to the manual 31 Term Description Electromagnetic interference FAIO-01 Optional analog I/O extension module FCAN Optional CANopen® adapter module FCNA-01 Optional ControlNet™ adapter module FDCO-01 DDCS communication module with two pairs of 10 Mbit/s DDCS channels FDIO-01 Optional digital I/O extension module FDNA-01 Optional DeviceNet™...
Page 32 32 Introduction to the manual Term Description ZBIB Adapter board connected to the control board in the control unit (ZCU) Type of control unit ZPOW Power supply board...
Page 33: Related Documents
Drive hardware manuals and guides Drive/converter/inverter safety instructions 3AXD50000037978 ACS880-04 drive modules (200 to 710 kW, 300 to 700 hp) 3AUA0000128301 hardware manual ACS880-04 drive modules (200 to 710 kW, 300 to 700 hp) 3AXD50000009366 quick installation guide ACx-AP-x Assistant control panels user’s manual...
Page 34 34 Introduction to the manual Name Code (Eng- Code (Transla- lish/Multilingual) tion) ACS880-01 drives and ACS880-04 drive modules com- 3AUA0000127818 mon DC systems application guide FOCH du/dt filters hardware manual 3AFE68577519 Sine filters hardware manual 3AXD50000016814 Manuals and quick guides for I/O extension modules, fieldbus adapters, etc.
Page 35: Operation Principle And Hardware Description
Operation principle and hardware description 35 Operation principle and hardware description Contents of this chapter This chapter describes the operation principle and construction of the drive module.
Page 36: Product Overview
36 Operation principle and hardware description Product overview The ACS880-04 is a drive module for controlling asynchronous AC induction motors, permanent magnet motors, AC induction servomotors and ABB synchronous reluctance motors (SynRM motors). The main circuit of the drive module is shown below.
Page 37: Layout
Operation principle and hardware description 37 Layout ￭ Standard drive module configuration with option +E208 Drive module Optional common mode filter (+E208) Upper front cover Pedestal Lower front cover External control unit with control panel holder Clear plastic shrouds attached Control panel See the next page for the part descriptions...
Page 38 38 Operation principle and hardware description +H370 Clear plastic shroud to be attached onto Fiber optic cables the drive module input power cabling (a). Entry shroud for side cabling (b). Clear plastic shrouds to be attached onto PE (ground) terminal the drive module output power cabling Clear plastic shroud to be attached on top Main cooling fans...
Page 39: Drive Module For Flat Mounting (Option +C173)
Operation principle and hardware description 39 Input power cable connection terminals Control panel (option +H370) Output power cable connection terminals Control cable clamp plate Grounding terminal for output power cable Cables for connecting the control unit to shields the drive module Metallic shroud.
Page 40 40 Operation principle and hardware description Flat mounting position (front view) Side view Flat mounting bracket (two pcs). The Bottom grille to be installed to the base of brackets are installed to the mounting plate the drive module for IP20 degree of protec- with 2×8 screws.
Page 41: Drive Module With Full Power Cabling Panels (Option +H381)
Operation principle and hardware description 41 ￭ Drive module with full power cabling panels (option +H381) 9× Accessories Assembled drive module Input power cabling panel Rubber grommet Side guides Input power cabling panel to be attached to the drive cabinet Output power cabling panel Output power cabling panel to be attached to the drive cabinet...
Page 42: Drive Module Without Full-Size Output Cable Connection Terminals (Option +0H371) And Ip20 Shrouds (Option +0B051)
42 Operation principle and hardware description Shim plates for Rittal VX25 enclosure (9 pcs) ￭ Drive module without full-size output cable connection terminals (option +0H371) and IP20 shrouds (option +0B051) Lifting lugs Fastening bracket Input cable connection busbars (L1/U1, L2/V1, L3/W1) and DC+ and DC- busbars (UDC+, UCD with option +H356) Circuit board compartment Output cable connection busbars (T1/U2, T2/V2, T3/W2) and brake resistor connection...
Page 43: Drive Module Configuration With Power Cable Connection Terminals On The Right-Hand Side Of The Drive Module (Option +H391)
Operation principle and hardware description 43 Handle for pulling the drive module out of the cabinet Optional common mode filter (+E208) PE busbar Pedestal guide plate Telescopic extraction/installation ramp Note: The front covers are removed in this photo, see number 11 in section Drive module with full power cabling panels (option +H381).
Page 44: Control Unit
44 Operation principle and hardware description Output cable connection busbars (T1/U2, T2/V2, T3/W2) and brake resistor connection busbars (R+ and R- with option +D150) Main cooling fans Pedestal Retractable support legs Base fastening screws Handle for pulling the drive module out of the cabinet PE busbar Pedestal guide plate Telescopic extraction/installation ramp...
Page 45 Operation principle and hardware description 45 For the use of the control panel, see the firmware manual or ACx-AP-x assistant control panels user’s manual (3AUA0000085685 [English]). For the control panel mounting platforms, see Mounting the control panel on the cabinet door (page 61).
Page 46: Overview Of Power And Control Connections
46 Operation principle and hardware description Overview of power and control connections The diagram shows the power connections and control interfaces of the drive module. Slot 1 Slot 2 X205 Slot 3 t° UDC+ UDC- T1/U2 L1/U1 T2/V2 L2/V1 T3/W2 L3/W1 1,2,3 Analog and digital I/O extension modules, feedback interface modules and fieldbus...
Page 47: Type Designation Label
Operation principle and hardware description 47 Type designation label The type designation label includes a rating, markings, a type designation and a serial number, which allow individual recognition of each drive module. The type designation label is located on the front cover. An example label is shown below. Type designation, see section Type designation key (page 47).
Page 48: Basic Code
48 Operation principle and hardware description ￭ Basic code Code Description ACS880 Product series Type When no options are selected: drive module to be installed in a cabinet, IP20 (UL Type Open), bookshelf mounting with pedestal, external control unit, ACS-AP-W control panel and panel holder, build-in choke, full-size output cable connection terminals, no EMC filter, no DC connection busbars, clear plastic shrouds for covering the input power and motor cable connections, ACS880 primary control program, Safe torque off...
Page 49 Operation principle and hardware description 49 Code Description D150 Brake choppers E200 EMC filter for 2nd environment TN (grounded) system, category C3 E201 EMC filter for second environment IT (ungrounded) system, category C3 E202 EMC filter for 1st environment TN (grounded) system, category C2 E208 Common mode filter 0H354...
Page 50 50 Operation principle and hardware description Code Description L500 FIO-11 analog I/O extension module (1, 2 or 3 pcs) L501 FIO-01 digital I/O extension module L502 FEN-31 HTL incremental encoder interface module L503 FDCO-01 optical DDCS communication adapter module L508 FDCO-02 optical DDCS communication adapter module L515 FEA-03 I/O extension adapter...
Page 51 Operation principle and hardware description 51 Code Description P905 Integrated control unit (inside drive module) Q971 ATEX-certified safe disconnection function Q972 FSO-21 safety functions module Q973 FSO-12 safety functions module PROFIsafe with FSO-xx safety functions module and FENA-21 Ethernet adapter Q982 module Q986...
Page 53: Generic Cabinet Planning Instructions
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.
Page 54: Disposition Of The Devices
￭ Shrouds The installation of shrouds (touch protection) to fulfill applicable safety regulations is the responsibility of the drive system builder. Ready-made shrouding parts are available from ABB for some cabinet designs, see the ordering information. ￭ Tightening torques Unless a tightening torque is specified in the text, the following torques can be used.
Page 55: Mechanical Connections
Generic cabinet planning instructions 55 Size Torque Strength class 22 N·m (16 lbf·ft) 42 N·m (31 lbf·ft) 70 N·m (52 lbf·ft) 120 N·m (90 lbf·ft) Mechanical connections Size Max. torque Strength class 6 N·m (53 lbf·in) 10 N·m (7.4 lbf·ft) 24 N·m (17.7 lbf·ft) Insulation supports Size...
Page 56: Air Inlets And Outlets
56 Generic cabinet planning instructions • leave enough free space around the components to ensure sufficient cooling. Observe the minimum clearances given for each component, see the technical data. ￭ Air inlets and outlets Equip the air inlets and outlets with gratings that: •...
Page 57: Preventing The Recirculation Of Hot Air
Generic cabinet planning instructions 57 • cooling air flow Note: The values stated for each component apply to continuous nominal load. If the load is cyclic or less than nominal, less cooling air may be required. • allowed surrounding air temperature and temperature rise inside the cabinet •...
Page 58: Emc Requirements
• The best galvanic connection between the steel panels is achieved by welding them together as no holes are necessary. If welding is not possible, ABB recommends to leave the seams between the panels unpainted and equipped with special conductive EMC strips to provide adequate galvanic connection.
Page 59 • 360° high-frequency grounding of the cable shields at the cable entries improves the EMC shielding of the cabinet. • ABB recommends 360° high-frequency grounding of the motor cable shields at their entries. The grounding can be implemented by a knitted wire mesh screening as shown below.
Page 60: Attaching The Cabinet
60 Generic cabinet planning instructions Attaching the cabinet WARNING! Do not attach the cabinet by electric welding. ABB does not assume any liability for damages caused by electric welding as the welding circuit can damage electronic circuits in the cabinet.
Page 61: Mounting The Control Panel On The Cabinet Door
Generic cabinet planning instructions 61 Mounting the control panel on the cabinet door You can use a mounting platform to mount the control panel on the cabinet door. Mounting platforms for control panels are available as options from ABB. For more information, see Manual...
Page 63: Guidelines For Planning The Mechanical Installation
Guidelines for planning the mechanical installation 63 Guidelines for planning the mechanical installation Contents of this chapter This chapter guides in planning drive cabinets and installing the drive module into a user-defined cabinet. The chapter gives cabinet layout examples and free space requirements around the module for cooling.
Page 64: Planning The Layout
Air outlet for the other equipment 2c*) Air outlet for the drive module and other equipment on the cabinet roof. An exhaust fan if needed. ABB recommends this alternative instead of 2a. Drive control panel with DPMP-01 mounting platform (option +J410).
Page 65: Layout Example, Door Open (Standard Drive Module Configuration)
Guidelines for planning the mechanical installation 65 ￭ Layout example, door open (standard drive module configuration) A – A Supporting frame of the cabinet Motor cable including the protective ground conductor of the drive module Drive module control unit. Vertical (2a) and horizontal (2b) air Note: With an integrated control unit (option baffles that separate the cool and hot +P905), the upper door air inlet is critical for...
Page 66: Layout Example, Door Open (Option +H391)
66 Guidelines for planning the mechanical installation Disconnector and fuses Air flow through the drive module Contactor Air flow to circuit boards and DC and output busbars Drive module Air flow to the brake option ￭ Layout example, door open (option +H391) A –...
Page 67 Guidelines for planning the mechanical installation 67 Input power cable including the protect- Air flow to the roof ive ground conductor (PE) of the drive Disconnector and fuses Air flow through the drive module Contactor Air flow to circuit boards and DC and output busbars Drive module Air flow to the brake option...
Page 68: Layout Example, Door Open (Option +0B051)
68 Guidelines for planning the mechanical installation ￭ Layout example, door open (option +0B051) This diagram shows a layout example for drive modules with no IP20 shrouds (option +0B051) or no cabling panels (option +H381 not included). L1/U1 L2/V1 L3/W1 T3/W2 T2/V2 T1/U2...
Page 69 Guidelines for planning the mechanical installation 69 Input power cable including the protect- Air flow to the roof ive ground conductor (PE) of the drive Disconnector and fuses Air flow through the drive module Contactor Air flow to circuit boards and DC and output busbars Drive module Air flow to the brake option...
Page 70: Bookshelf Mounting (Standard Drive Module Configuration)
70 Guidelines for planning the mechanical installation ￭ Bookshelf mounting (standard drive module configuration) This diagram shows the air baffle position inside an example cabinet. For dimensions of the baffle, see Air baffles for the standard drive module and option +C173 (page 259).
Page 71: Bookshelf Mounting (Option +0B051)
Guidelines for planning the mechanical installation 71 Optional air baffle that is needed when Note: The upper grating in the cabinet door must there is no fan on the lower part of the be located in the area marked with the horizontal cabinet door (see 1b (page 64))
Page 72 72 Guidelines for planning the mechanical installation C – C A - A B - B D – D...
Page 73: Bookshelf Mounting (Option +H381)
Guidelines for planning the mechanical installation 73 Air flow to the drive module, max. Drive module 40 °C (104 °F) Air flow to the drive circuit boards and Disconnector and fuses DC and output busbars Vertical air baffle that separates the Contactor cool and hot areas in the cabinet Vertical air baffle...
Page 74: Flat Mounting (Option +C173)
74 Guidelines for planning the mechanical installation ￭ Flat mounting (option +C173) This diagram shows the air baffle position inside an example cabinet. For dimensions of the baffle, see Air baffles for the standard drive module and option +C173 (page 259).
Page 75: Flat Mounting (Option +C173 + 0B051)
Guidelines for planning the mechanical installation 75 ￭ Flat mounting (option +C173 + 0B051) This diagram shows the air baffle position inside an example cabinet. A – A C – C B – B Air flow to the drive module, max. Disconnector and fuses 40 °C (104 °F) Air flow to the drive circuit boards and...
Page 76: Free Space Requirements
76 Guidelines for planning the mechanical installation Vertical air baffle Air gap between the drive module front and cabinet wall for cooling air flow Vertical air baffle that guides air flow Cabinet grounding busbar (PE) to the inside the drive module Drive module Free space requirements Free space around the drive module is needed to make sure that sufficient cooling air...
Page 77: Free Space Around The Drive Module
You can install the drive module on its back. Make sure that the hot cooling air that flows upwards from the module does not cause danger. For other installation positions, contact ABB. Placement of the control panel Note the following alternatives when you plan the placement of the control panel: •...
Page 79: Mechanical Installation
Mechanical installation 79 Mechanical installation Contents of this chapter This chapter describes how to install the drive module mechanically without the clear plastic shrouds. The shrouds are attached after the power cabling. Safety WARNING! Lift the drive module only by the lifting lugs: Make sure that the module does not topple over when you move it on the floor: To open the support legs, press each leg a little down (1, 2) and turn it aside.
Page 80: Examining The Installation Site
80 Mechanical installation 3AUA0000086323 Examining the installation site Examine the installation site. Make sure that: • The installation site is sufficiently ventilated or cooled to remove heat from the drive. See the technical data. • The ambient conditions of the drive meet the specifications. See the technical data. Moving and unpacking the unit WARNING! Obey the safety instructions of the drive.
Page 81 Mechanical installation 81...
Page 82: Package Drawings
82 Mechanical installation ￭ Package drawings 3AUA0000101742 Transport package contents With standard drive module configuration: Clear plastic shrouds. With option +H381: Input cabling panel parts. See below for the box contents. With standard drive module configuration: Output cable connection terminals. With option +H370 also input cable connection terminals.
Page 83 Mechanical installation 83 Drive module with factory installed options and multilingual residual voltage warning sticker, top guide plate, pedestal guide plate, telescopic ramp package, fastening screws in a plastic bag, external control unit with control cable clamp plate and factory installed optional modules, control panel and cable or control panel with door mounting kit (option +J410), delivery documents, printed multilingual installation and start-up quick guides and manuals CD.
Page 84 84 Mechanical installation Box B1 contents (standard drive module configuration) Paper fill Clear plastic shroud for output cabling Cardboard box cover Cardboard box bottom Support Bands Back clear plastic shroud (lower) Back clear plastic shroud (upper) Front clear plastic shroud Clear plastic shroud for input cabling Top clear plastic shroud...
Page 85 Mechanical installation 85 Box B2 contains this box with standard drive module configura- tion Paper fill Output cable connection terminal T3/W2 Output cable connection terminal T2/V2 Output cable connection terminal T1/U2 Grounding terminal Cardboard box Screws and insulators in a plastic 3AXD5000009515 Ramp box contents Screw package...
Page 86 86 Mechanical installation Accessories box contents Screw package, includes also spacers for FSO module installa- tion Rubber grommets for control unit cable entry holes in the middle front cover of the drive module Bracket for attaching the drive module from top Cardboard box 3AXD50000453894 Flat installation box contents (op-...
Page 87: Examining The Delivery
For an installation example on how to install the drive module with clear plastic shrouds into a Rittal VX25 enclosure, see Installation example of the standard drive module configuration (page 157). See also ACS880-04 drive modules (200 to 710 kW, 300 to 700 hp) quick installation guide (3AXD50000009366 [English]).
Page 88: Optional Input Power Cable Connection Terminals And Ground Busbar Assembly (+H370)
88 Mechanical installation Note: For option +0H354 (no pedestal): Make sure that the cabinet mounting plate and frame are strong enough to carry the weight of the drive module. See section Dimensions, weights and free space requirements (page 225). For an installation example on how to install the drive module without pedestal in flat position in a Rittal VX25 enclosure, see Step-by-step drawings for a flat installation example in a Rittal 600 mm wide enclosure (page...
Page 89: Drive Module Without Full-Size Output Cable Connection Terminals (Option +0H371) And Ip20 Shrouds (Option +0B051)
Mechanical installation 89 Note: This installation alternative is not possible without pedestal (with option +0H354). ￭ Drive module without full-size output cable connection terminals (option +0H371) and IP20 shrouds (option +0B051) The power cables can be connected directly to the drive module input and output terminals with cable lugs or by busbars.
Page 90: Attaching The Drive Module To A Mounting Plate Or Wall (Option +H391)
90 Mechanical installation M4×12 Torx ￭ Attaching the drive module to a mounting plate or wall (option +H391) Step-by-step drawings for option +H391 installation example in a Rittal 600 mm wide enclosure (page 313). ￭ Attaching the external control unit The drive control unit can be fastened on a mounting plate through the fastening holes in its back or by using a DIN rail.
Page 91: Attaching The External Control Unit To A Mounting Plate Or Wall
Mechanical installation 91 Attaching the external control unit to a mounting plate or wall 1. Attach the mounting screws in the wall. 2. Lift the control unit onto the screws and tighten the screws. 3AUA0000130997 Attaching the external control unit vertically on a DIN rail 1.
Page 92: Attaching The External Control Unit Horizontally On A Din Rail
92 Mechanical installation 3AUA0000130997 Attaching the external control unit horizontally on a DIN rail 1. Attach the latches (A) to the back of the control unit with three screws. 2. Click the control unit to the rail as shown below (B). 3AUA0000130997 ￭...
Page 93 Mechanical installation 93 1. from the grounding hole 2. to a Rittal punched section: with fastening bracket. Tapping screw M6×12 Torx T30 (Hex) 9 N·m...
Page 94: Installing The Bottom Grille For Ip20 Degree Of Protection
94 Mechanical installation ￭ Installing the bottom grille for IP20 degree of protection If IP20 degree of protection is needed from the bottom side, install the bottom grille as shown below.
Page 95: Guidelines For Planning The Electrical Installation
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.
Page 96: European Union
Examining the compatibility of the motor and drive Use asynchronous AC induction motors, permanent magnet synchronous motors, AC induction servomotors or ABB synchronous reluctance motors (SynRM motors) with the drive. Select the motor size and drive type from the rating table on basis of the AC line voltage and motor load.
Page 97: Protecting The Motor Insulation And Bearings
Guidelines for planning the electrical installation 97 Note: • Consult the motor manufacturer before using a motor whose nominal voltage differs from the AC line voltage connected to the drive input. • The voltage peaks at the motor terminals are relative to the supply voltage of the drive, not the drive output voltage.
Page 98 98 Guidelines for planning the electrical installation This table shows the requirements when an ABB motor is in use. Motor type Nominal AC sup- Requirement for ply voltage Motor insu- ABB du/dt and common mode filters, in- lation sys- sulated N-end motor bearings P n <...
Page 99 Guidelines for planning the electrical installation 99 This table shows the requirements when a non-ABB motor is in use. Motor type Nominal AC sup- Requirement for ply voltage Motor insu- ABB du/dt and common mode filters, in- lation sys- sulated N-end motor bearings P n <...
Page 100: Availability Of Du/Dt Filter And Common Mode Filter By Drive Type
If you will use an explosion-safe (EX) motor, follow the rules in the requirements table above. In addition, consult the motor manufacturer for any further requirements. Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and AM_ Use the selection criteria given for non-ABB motors.
Page 101: Additional Requirements For Non-Abb High-Output And Ip23 Motors
The rated output power of high-output motors is higher than what is stated for the particular frame size in EN 50347 (2001). If you plan to use a non-ABB high-output motor or an IP23 motor, consider these additional requirements for protecting the motor insulation and bearings in drive systems: •...
Page 102: Additional Data For Calculating The Rise Time And The Peak Line-To-Line Voltage
102 Guidelines for planning the electrical installation Nominal AC supply Requirement for voltage Motor insulation sys- ABB du/dt and common mode filters, insu- lated N-end motor bearings P n < 100 kW or frame 100 kW < P n < 350 kW size < IEC 315 IEC 315 <...
Page 103: Additional Note For Sine Filters
Guidelines for planning the electrical installation 103 Û du/dt -------------(1/ µs) Û -- - - -- - - - - - (1/ µs) l (m) l (m) Drive with du/dt filter Drive without du/dt filter Motor cable length Û LL /U N Relative peak line-to-line voltage (du/dt)/U N Relative du/dt value...
Page 104: Typical Power Cable Sizes
104 Guidelines for planning the electrical installation Symmetrical shielded cable reduces electromagnetic emission of the whole drive system as well as the stress on motor insulation, bearing currents and wear. Metal conduit reduces electromagnetic emission of the whole drive system. The protective conductor must always have an adequate conductivity.
Page 105: Power Cable Types
Guidelines for planning the electrical installation 105 ￭ Power cable types Preferred power cable types This section presents the preferred cable types. Make sure that the selected cable type also complies with local/state/country electrical codes. Cable type Use as input power cabling Use as motor cabling Symmetrical shielded (or ar- mored) cable with three phase...
Page 106: Alternate Power Cable Types
106 Guidelines for planning the electrical installation Alternate power cable types Cable type Use as input power cabling Use as motor cabling Yes with phase conductor Yes with phase conductor smaller than 10 mm 2 (8 AWG) smaller than 10 mm 2 (8 AWG) Cu, or motors up to 30 kW (40 hp).
Page 107: Not Allowed Power Cable Types
￭ Additional guidelines, North America ABB recommends the use of conduit for power wiring to the drive and between the drive and the motor(s). Due to the variety of application needs, metallic and non-metallic conduit can be used. ABB recommends the use of metallic conduit.
Page 108: Metal Conduit
108 Guidelines for planning the electrical installation Wiring method Notes Free air Prefer symmetrical shielded VFD cable. Enclosures, air handlers, etc. Allowed internally in enclosures when in accord- ance with UL. 1) Metallic conduit may be used as an additional ground path, provided this path is a solid path capable of handling ground currents.
Page 109: Selecting The Control Cables
￭ Relay cable The cable type with braided metallic shield (for example ÖLFLEX by LAPPKABEL, Germany) has been tested and approved by ABB. ￭ Control panel to drive cable Use EIA-485 with male RJ-45 connector, cable type Cat 5e or better. The maximum permitted length of the cable is 100 m (328 ft).
Page 110: Routing The Cables
110 Guidelines for planning the electrical installation Routing the cables ￭ General guidelines – IEC • Route the motor cable away from other cables. Motor cables of several drives can be run in parallel installed next to each other. • Install the motor cable, input power cable and control cables on separate trays. •...
Page 111: General Guidelines - North America
Guidelines for planning the electrical installation 111 ￭ General guidelines – North America Make sure that the installation is in accordance with national and local codes. Obey these general guidelines: • Use separate conduits for the input power, motor, brake resistor (optional), and control cabling.
Page 112: Continuous Motor Cable Shield/Conduit Or Enclosure For Equipment On The Motor Cable
112 Guidelines for planning the electrical installation ￭ Continuous motor cable shield/conduit or enclosure for equipment on the motor cable To minimize the emission level when safety switches, contactors, connection boxes or similar equipment are installed on the motor cable between the drive and the motor: •...
Page 113: Tested Circuit Breakers
You can use the circuit breakers listed in the technical data. Other circuit breakers can be used with the drive if they provide the same electrical characteristics. ABB does not assume any liability whatsoever for the correct function and protection with circuit breakers not listed.
Page 114: Protecting The Motor Against Overload Without Thermal Model Or Temperature Sensors
These capacitors and long motor cables increase the ground leakage current and may cause nuisance faults in residual current devices. Connecting drive modules to a common DC system See ACS880-01 drives and ACS880-04 drive modules common DC systems application guide (3AUA0000127818...
Page 115: Implementing A Motor Temperature Sensor Connection
Guidelines for planning the electrical installation 115 Implementing a motor temperature sensor connection WARNING! IEC 60664 and IEC 61800-5-1 require double or reinforced insulation between live parts and accessible parts when: • the accessible parts are not conductive, or • the accessible parts are conductive, but not connected to the protective earth. Obey this requirement when you plan the connection of the motor temperature sensor to the drive.
Page 116: Implementing The Emergency Stop Function
116 Guidelines for planning the electrical installation • temperature sensor types that you can connect to each option module • temperature sensor insulation requirement in order to form, together with the insulation of the option module, a reinforced insulation between the motor live parts and the drive control unit.
Page 117: Implementing The Functions Provided By The Fso-Xx Safety Functions Module
Guidelines for planning the electrical installation 117 Implementing the functions provided by the FSO-xx safety functions module You can order the drive with an FSO-12 or FSO-21 safety functions module (option +Q972 or +Q973) which enables the implementation of functions such as Safe brake control (SBC), Safe stop 1 (SS1), Safe stop emergency (SSE), Safely limited speed (SLS) and Safe maximum speed (SMS).
Page 118: Using A Safety Switch Between The Drive And The Motor
118 Guidelines for planning the electrical installation Using a safety switch between the drive and the motor ABB recommends to install a safety switch between the permanent magnet motor and the drive output. The switch is needed to isolate the motor from the drive during maintenance work on the drive.
Page 119: Controlling A Contactor Between Drive And Motor
Guidelines for planning the electrical installation 119 3. Enable the automatic restart of the motor after a short power supply break: • Set the start mode to automatic (parameter 21.01 or 21.19, depending on the motor control mode being used). •...
Page 120: Example Bypass Connection
120 Guidelines for planning the electrical installation WARNING! Never connect the drive output to the electrical power network. The connection may damage the drive. ￭ Example bypass connection An example bypass connection is shown below. Drive main switch Bypass circuit breaker Drive main contactor Bypass contactor Drive output contactor...
Page 121: Switching The Motor Power Supply From Drive To Direct-On-Line
Guidelines for planning the electrical installation 121 Switching the motor power supply from drive to direct-on-line 1. Stop the drive and the motor with the drive control panel stop key (drive in the local control mode) or the external stop signal (drive in the remote control mode). 2.
Page 122 122 Guidelines for planning the electrical installation 230 V AC 230 V AC + 24 V DC Relay output Varistor RC filter Diode...
Page 123: Electrical Installation
Electrical installation 123 Electrical installation Contents of this chapter This chapter contains instructions for electrical installation of the drive module. The chapter refers to installation example chapters which contain instructions that depend on the selected drive configuration. Safety WARNING! If you are not a qualified electrical professional, do not do installation or maintenance work.
Page 124: Measuring The Insulation
Use a measuring voltage of 1000 V DC. The insulation resistance of an ABB motor must be more than 100 Mohm (reference value at 25 C [77°F]). For the insulation resistance of other motors, refer to the manufacturer’s instructions.
Page 125: Measuring The Insulation Of The Brake Resistor Circuit
Electrical installation 125 ￭ Measuring the insulation of the brake resistor circuit WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work.
Page 126: Corner-Grounded And Midpoint-Grounded 525
126 Electrical installation ￭ Corner-grounded and midpoint-grounded 525…690 V delta systems WARNING! Do not install the drive on a 525…690 V corner-grounded or midpoint-grounded delta system. Disconnecting the EMC filter and ground-to-phase varistor does not prevent damage to the drive Installing the EMC filter (option +E202) See ARFI-10 EMC filter installation guide (3AFE68317941...
Page 127: Power Cable Connection Diagram
Electrical installation 127 ￭ Power cable connection diagram (PE) PE (PE) ACS880-04 L2/ L3/ UDC- UDC+ INPUT OUTPUT Disconnecting device, see Selecting the main supply disconnecting device (page 95). In the installing example of this chapter, the disconnecting device is not in the same cubicle with the drive module.
Page 128: Preparing The Cable Ends And Making 360-Degree Grounding At The Cable Entry
128 Electrical installation ABB recommends 360-degree grounding at the cabinet entry if a shielded cable is used. Ground the other end of the input cable shield or PE conductor at the distribution board. ABB recommends 360-degree grounding at the cabinet entry, see EMC requirements on page Use a separate grounding cable if the conductivity of the cable shield is <...
Page 129 Electrical installation 129 WARNING! Apply grease to stripped aluminum conductors before attaching them to non-coated aluminum cable lugs. Obey the grease manufacturer’s instructions. Aluminum-aluminum contact can cause oxidation in the contact surfaces. 3. If fire insulation is used, make an opening in the mineral wool sheet according to the diameter of the cable.
Page 130: Power Cable Connection Procedure
The UDC+ and UDC– terminals are intended for common DC configurations of a number of drives, allowing regenerative energy from one drive to be utilized by the other drives in the motoring mode. See ACS880-01 drives and ACS880-04 drive modules common DC systems application guide (3AUA0000127818 [English]).
Page 131: Attaching The Control Cable Clamp Plate
Electrical installation 131 Attaching the control cable clamp plate Attach the control cable clamp plate either to the top or base of the control unit with four screws as shown below. Note: If you install the FSO-xx safety functions module above the control unit, attach the control cable clamp plate on the base of the control unit.
Page 132: Connecting The External Control Unit To The Drive Module
132 Electrical installation 0.7 N·m (6.2 lbf·in) Connecting the external control unit to the drive module WARNING! Handle the fiber optic cables with care. When unplugging optic cables, always grab the connector, not the cable itself. Do not touch the ends of the fibers with bare hands as the fiber is extremely sensitive to dirt.
Page 133 Electrical installation 133 ZPOW BGDR V10, V20...
Page 134: Connections To The Control Unit
134 Electrical installation ￭ Connections to the control unit Connect the fiber optic, power supply and BGDR cables to the control unit as follows: 1. Thread the cables inside the back frame of the control unit. 2. Connect the cables to the ZBIB board terminals. ZPOW ZBIB SOIA...
Page 135: Connecting The Control Cables To The Terminals Of The External Control Unit
Electrical installation 135 ZBIB X3:3 X3:2 X3:1 ZPOW (STO2) (STO1) BGDR SOIA RXD = receiver TXD = transmitter Connecting the control cables to the terminals of the external control unit 1. Route the cables to the control unit as shown below.
Page 136 136 Electrical installation 2. Ground the shields of the control cables at the clamp plate. Use torque 1.5 N·m (13 lbf·in). The shields should be continuous as close to the terminals of the control unit as possible. Only remove the outer jacket of the cable at the cable clamp so that the clamp presses on the bare shield.
Page 137: Connecting The Control Cables To The Integrated Control Unit (Option +P905)
Electrical installation 137 Connecting the control cables to the integrated control unit (option +P905) 1. Ground the outer control cable shields 360 degrees at the cabinet entry plate (recommendation). 2. Remove the middle front cover of the drive module (view of standard drive module configuration below).
Page 138: Connecting The Control Cables To The Integrated Control Unit (Options +P905 And +0B051)
138 Electrical installation Combi screw M4×8 Torx T20 2 N·m Connecting the control cables to the integrated control unit (options +P905 and +0B051) 1. Remove the middle front cover of the drive module. 2. Attach the clamp plate to the control unit with two screws from front, see Attaching the control cable clamp plate (page 131).
Page 139: Connecting A Control Panel
Electrical installation 139 tubing or insulating tape to contain any stray strands. Tighten the screws to secure the connection. Note: Keep any signal wire pairs twisted as close to the terminals as possible. Twisting the wire with its return wire reduces disturbances caused by inductive coupling.
Page 140: Panel Bus (Control Of Several Units From One Control Panel)
140 Electrical installation Note: When a PC is connected to the control panel, the control panel keypad is disabled. In this case, the control panel acts as a USB-RS485 adapter. Panel bus (Control of several units from one control panel) One control panel (or PC) can be used to control several drives (or inverter units, supply units etc.) by constructing a panel bus.
Page 141 Electrical installation 141 4. On the control panel, switch on the panel bus functionality (Options - Select drive - Panel bus). The drive to be controlled can now be selected from the list under Options - Select drive. If a PC is connected to the control panel, the drives on the panel bus are automatically displayed in the Drive composer tool.
Page 142 142 Electrical installation With FDPI-02 modules:...
Page 143: Connecting A Pc
Electrical installation 143 Connecting a PC WARNING! Do not connect the PC directly to the control panel connector of the control unit as this can cause damage. A PC (with eg, the Drive composer PC tool) can be connected as follows: 1.
Page 144 144 Electrical installation 2. If the bottom plate of the FSO-xx module looks different from that in the drawing below, remove the bottom plate and attach the alternative bottom plate from the FSO package to module. 3. Connect the FSO-xx data cable to connector X12 on the control unit. 4.
Page 145: Installing I/O Extension, Fieldbus Adapter And Pulse Encoder Interface Modules
Electrical installation 145 ￭ Installing I/O extension, fieldbus adapter and pulse encoder interface modules See section Overview of power and control connections for the available slots for each module. WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.
Page 147: Control Unit
Control unit 147 Control unit Contents of this chapter This chapter • describes the connections of the control unit(s) used in the drive, • contains the specifications of the inputs and outputs of the control unit(s).
Page 148: Zcu-14 Layout
148 Control unit ZCU-14 layout Description XPOW External power input XRO1 Analog inputs Analog outputs XRO2 XD2D Drive-to-drive link XRO1 Relay output RO1 XRO3 XRO2 Relay output RO2 XRO3 Relay output RO3 XPOW XD24 Digital input interlock (DIIL) and +24 V J1, J2 output XDIO...
Page 149: Default I/O Diagram Of The Drive Control Unit (Zcu-1X)
Control unit 149 Default I/O diagram of the drive control unit (ZCU-1x) Connection Term Description XPOW External power input +24VI 24 V DC, 2 A min. (without optional modules) J1, J2, XAI Reference voltage and analog inputs +VREF 10 V DC, R L 1…10 kohm +VREF -VREF -10 V DC, R L 1…10 kohm...
Page 150 150 Control unit Connection Term Description XD24 Auxiliary voltage output, digital interlock DIIL Run enable DIIL +24VD +24VD +24 V DC 200 mA DICOM DICOM Digital input ground +24VD +24VD DIOGND +24 V DC 200 mA DIOGND Digital input/output ground XDIO Digital input/outputs DIO1 Output: Ready run...
Page 151: Additional Information On The Connections
Control unit 151 Additional information on the connections ￭ External power supply for the control unit (XPOW) The control unit is powered from a 24 V DC, 2 A supply through terminal block XPOW. Using an external supply is recommended if •...
Page 152: Diil Input
152 Control unit 3.3 nF / 630 V. The shield can also be grounded directly at both ends if they are in the same ground line with no significant voltage drop between the end points. AI1+ AI1- AGND One, two or three Pt100, Pt1000 or PTC sensors; or one KTY84 sensor Set the input type to voltage with the appropriate switch or jumper on the control unit.
Page 153: Safe Torque Off (Xsto)
(nominal impedance 100 to 165 ohm, for example Belden 9842) for the wiring. For best immunity, ABB recommends high quality cable. Keep the cable as short as possible. Avoid unnecessary loops and parallel runs near power cables such as motor cables.
Page 154: Connector Data
154 Control unit Connector data This data applies also to integrated control unit (option +P905) connectors. Connector pitch 5 mm, wire size 2.5 mm 2 Power supply (XPOW) 24 V (±10%) DC, 2 A External power input. Connector pitch 5 mm, wire size 2.5 mm 2 Relay outputs RO1…RO3 (XRO1…XRO3) 250 V AC / 30 V DC, 2 A...
Page 155 Control unit 155 Connector pitch 5 mm, wire size 2.5 mm 2 Analog inputs AI1 and AI2 (XAI:4 … XAI:7). Current input: –20…20 mA, R in = 100 ohm Current/voltage input mode selec- Voltage input: –10…10 V, R in > 200 kohm tion by jumpers Differential inputs, common mode range ±30 V Sampling interval per channel: 0.25 ms...
Page 156: Zcu-1X Ground Isolation Diagram
156 Control unit ￭ ZCU-1x ground isolation diagram XPOW +24VI +VREF -VREF AGND AI1+ Common mode voltage between AI1- channels ±30 V AI2+ AI2- AGND AGND XD2D BGND XRO1, XRO2, XRO3 XD24 DIIL +24VD DICOM +24VD DIOGND XDIO DIO1 DIO2 XSTO OUT1 * Ground selector (J6) settings...
Page 157: Installation Example Of The Standard Drive Module Configuration
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.
Page 158: Required Parts
VX 8606.000 Enclosure without mounting plate, bottom plates and side panels. DK 7967.000 Spacers for roof plates. / ABB roof (one set = four pieces) Note: For alternative ABB outlet kits, see section Air outlet ABB 3AUA0000117003 kits (page 208). (IP20)
Page 159: Overall Flowchart Of The Installation Process
See a video of the installation at YouTube: http://www.youtube.com/watch?v=IhKOSx3HmzQ Step-by-step drawings for an installation example of standard drive configuration with option +E208 in Rittal VX25 600 mm wide enclosure (page 299) and ACS880-04 quick installation guide (3AXD50000009366 [English]). • Install the punched section to the back of the enclosure frame.
Page 160: Connecting The Power Cables And Installing The Shrouds
160 Installation example of the standard drive module configuration • To prevent the drive module from falling, attach its lifting lugs with chains to the enclosure frame. • Push the drive module carefully into the enclosure along the telescopic insertion ramp.
Page 161 Installation example of the standard drive module configuration 161 Step drill carefully sufficiently big holes to the entry clear plastic shroud for the cables to be connected. Align the holes in the vertical direction according to the alignment holes in the shroud. Smooth the hole edges. Remove the plastic sheeting from both sides of the shroud.
Page 162: Installing The Roof And Door (Rittal Parts)
162 Installation example of the standard drive module configuration Installing the roof and door (Rittal parts) This drawing shows a layout tested by ABB. Rittal 7967.000 Rittal 3326.200 592 [23.31] 3AUA0000145776 Door Install these gratings as close to each other as possible. Remove the filter mats.
Page 163: Installing The Roof And Door (Abb Air Filters And Roof)
Installation example of the standard drive module configuration 163 Installing the roof and door (ABB air filters and roof) This drawing shows a layout tested by ABB. ABB 3AUA0000125202 (IP20) ABB 3AUA0000114971 (IP42) ABB 3AUA0000117003 (IP20) ABB 3AUA0000117008 (IP42) 3AXD50000016652...
Page 164: Removing The Protective Covering From The Drive Module Air Outlet
164 Installation example of the standard drive module configuration Removing the protective covering from the drive module air outlet WARNING! Remove the protective covering from the top of the drive module after the installation. If the covering is not removed, the cooling air cannot flow freely through the module and the drive will run to overtemperature.
Page 165: Installation Example With Full Cabling Panels (Option +H381)
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.
Page 166: Required Parts
VX 8106.245 Side panels for the enclosure DK 7967.000 Spacers for roof plate / ABB roof (one set = four pieces) Note: For alternative ABB outlet kits, see section Air outlet ABB 3AUA0000125201 kits (page 208). (IP20) ABB 3AUA0000114967 (IP42) VX 8617.030...
Page 167: Required Tools
Installation example with full cabling panels (option +H381) 167 3AXD50000433988 Cabinet bottom plate (alternative to Rittal support rails) See section Bottom plate for option +H381 in Rittal VX25 400 mm wide enclosure installation (page 257) for the di- mension drawing of a customer-made bottom plate Required tools •...
Page 168: Connecting The Power Cables
Note: If the thickness of the bottom plate is not 2.5 mm (0.1 in), adjust the dimensions accordingly. Connecting the power cables ￭ Power cable connection diagram (PE) PE (PE) ACS880-04 L1/U1 L2/V1 L3/W1 UDC- UDC+ L1/U1 L2/V1 L3/W1 UDC-...
Page 169: Power Cable Connection Procedure
< 50% of the conductivity of the phase conductor, use a separate PE cable (2a) or a cable with a grounding conductor (2b). ABB recommends 360-degree grounding at the cabinet entry if a shielded cable is used. Ground the other end of the input cable shield or PE conductor at the distribution board.
Page 170 170 Installation example with full cabling panels (option +H381) 5. Make sure that all power is disconnected and reconnection is not possible. Use proper safe disconnect procedures according to local codes. 6. Run the input cables from the supply source to the enclosure. Ground the cable shields 360°...
Page 171 Installation example with full cabling panels (option +H381) 171 360-degree grounding at the entry plate for the input power cables Grounding busbar of the input power cabling panel 360-degree grounding at the entry plate for the output power cables Grounding busbar of the output power cabling panel Allowed space for power cables.
Page 172: Installing The Drive Module Into The Enclosure
172 Installation example with full cabling panels (option +H381) Installing the drive module into the enclosure WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. Handle the drive module carefully. Make sure that the module does not fall down when moving it on the floor and during installation and maintenance work: To open the support legs, press each leg a little down and turn it aside (1, 2).
Page 173 Installation example with full cabling panels (option +H381) 173 M8×20 Hex 2. Install the telescopic extraction and insertion ramp to the cabinet base with two screws. 3. Remove the upper and lower left-hand side front covers of the drive module (M4×8 combi screws, 2 N·m).
Page 174 174 Installation example with full cabling panels (option +H381) 7. Connect the busbars of the drive module to the busbars of the cabling panels (M12 combi screw, 70 N·m [52 bf·ft]). 8. Attach the drive module to the enclosure from top and bottom, see Assembly drawing of installing the drive module to the enclosure (frame R10) (page 176) (frame R10)
Page 175 Installation example with full cabling panels (option +H381) 175...
Page 176: Assembly Drawing Of Installing The Drive Module To The Enclosure (Frame R10)
176 Installation example with full cabling panels (option +H381) Assembly drawing of installing the drive module to the enclosure (frame R10)
Page 177: Assembly Drawing Of Installing The Drive Module To The Enclosure (Frame R11)
Installation example with full cabling panels (option +H381) 177 Assembly drawing of installing the drive module to the enclosure (frame R11)
Page 178: Assembly Drawing Of Installing The Roof And Door
178 Installation example with full cabling panels (option +H381) Assembly drawing of installing the roof and door This drawing shows a layout tested by ABB. If you use ABB air filters, place them vertically in the positions shown in Installing the roof and door (ABB air filters and roof) (page 163).
Page 179: Removing The Protective Covering From The Drive Module Air Outlet
Installation example with full cabling panels (option +H381) 179 ￭ Removing the protective covering from the drive module air outlet WARNING! Remove the protective covering from the top of the drive module after the installation. If the covering is not removed, the cooling air cannot flow freely through the module and the drive will run to overtemperature.
Page 180: Miscellaneous
180 Installation example with full cabling panels (option +H381) Miscellaneous ￭ Installations with input and motor cables of size 4 × 240 mm per phase If resistor cables are to be connected, the lower side plate of the output cabling panel must be removed and the resistor cables lead from side to the terminals of the output cabling panel.
Page 181: Installation Checklist
Installation checklist 181 Installation checklist Contents of this chapter This chapter contains a list for examining the mechanical and electrical installation of the drive. Checklist Examine the mechanical and electrical installation of the drive before start-up. Go through the checklist together with another person. WARNING! Obey the safety instructions.
Page 182 182 Installation checklist Make sure that … Drive option modules and other components Type and number of option modules and other equipment is correct. Option modules and other equipment are not damaged. Option modules and terminals are labeled correctly. The placement of optional modules and other equipment inside the cabinet and on the cabinet door is correct.
Page 183 Installation checklist 183 Make sure that … The type designation labels and warning and instruction stickers are made according to the local regulations and placed correctly. Switches and doors Mechanical switches, main disconnecting switch and cabinet doors function properly. Installation of the cabinet The drive cabinet has been attached to floor and also from top to the wall or roof.
Page 184 184 Installation checklist Make sure that … If a drive bypass connection will be used: The direct-on-line contactor of the motor and the drive output contactor are either mechanically or electrically interlocked, ie, cannot be closed simultaneously. There are no tools, foreign objects or dust from drilling inside the drive. All shrouds and cover of the motor connection box are in place.
Page 185: Start-Up
• For drives with resistor braking (option +D150): See also section Start-up in Resistor braking. • For drives with ABB du/dt filter: Check that bit 13 of parameter 95.20 HW options word 1 is switched on. • For drives with ABB sine filter: Check that parameter 95.15 Special HW settings is set to ABB sine filter.
Page 186 186 Start-up 5. For drives with ABB motors in explosive atmospheres: See also ACS880 drives with ABB motors in explosive atmospheres (3AXD50000019585 [English]). 6. For drive modules in which the Safe torque off function is in use: Test and validate the operation of the Safe torque off function.
Page 187: Fault Tracing
Fault tracing 187 Fault tracing Contents of this chapter This chapter describes the fault tracing possibilities of the drive. LEDs The table below describes the LEDs of the drive module with option +J410. Where Color When the LED is lit Control panel POWER Green...
Page 189: Maintenance
(www.abb.com/drivesservices). For more information, consult your local ABB Service representative (www.abb.com/searchchannels). The maintenance and component replacement intervals are based on the assumption that the equipment is operated within the specified ratings and ambient conditions. ABB recommends annual drive inspections to ensure the highest reliability and optimum performance.
Page 190: Recommended Annual Maintenance Actions By The User
190 Maintenance ￭ Recommended annual maintenance actions by the user ABB recommends these annual inspections to ensure the highest reliability and optimum performance. Recommended annual actions by the user Annu- ally Connections and environment Quality of supply voltage Spare parts...
Page 191: Cabinet
Maintenance 191 Cabinet ￭ Cleaning the interior of the cabinet WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. WARNING! Use a vacuum cleaner with antistatic hose and nozzle, and wear a grounding wristband.
Page 192 192 Maintenance 1. Stop the drive and do the steps in section Electrical safety precautions (page 20) before you start the work. 2. Make sure that the drive is disconnected from the power line and all other precautions described under Grounding have been taken into consideration.
Page 193: Fans
See the firmware manual for the actual signal which indicates the running time of the cooling fan. Reset the running time signal after fan replacement. Replacement fans are available from ABB. Do not use other than ABB specified spare parts. ￭...
Page 194: Replacing The Main Cooling Fans
194 Maintenance ￭ Replacing the main cooling fans WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Electrical safety precautions (page 20) before you start the work.
Page 195 Maintenance 195...
Page 196: Replacing The Standard Drive Module
196 Maintenance Replacing the standard drive module WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. Note: The replacement module must be of the same type as the original module: same type code and same option codes.
Page 197: Replacing The Drive Module With Option +H381
Maintenance 197 4. Disconnect the power supply, BGDR and fiber optic cables from the drive module. 5. Disconnect the power supply cable and the fiber optic cables from the external control unit and coil them on the top of the drive module. 6.
Page 198 198 Maintenance 3AUA0000086323 1. Stop the drive and do the steps in section Electrical safety precautions (page 20) before you start the work. 2. Remove the left-hand side upper and lower front covers of the drive module by undoing the fastening screws. M4×10 combi screws, 2 N·m. For drive modules with an integrated control unit (option +P905) and control panel (option +J414): Remove the control panel and the control panel cable from the integrated control unit.
Page 199 Maintenance 199 9. To prevent the drive module from falling, attach its top lifting lugs with chains to the cabinet frame. 10. Pull the drive module carefully out of the cabinet preferably with help from another person. 11. Install the new module in reverse order to the above.
Page 200: Capacitors
Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. If you think that any capacitors in the drive have failed, contact ABB. ￭...
Page 201: Replacing The Zcu-14 Control Unit Battery
Maintenance 201 Replacing the ZCU-14 control unit battery WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. 1.
Page 202: Replacing The Memory Unit Of Zcu-14
202 Maintenance Replacing the memory unit of ZCU-14 After replacing a control unit, you can retain the existing parameter settings by transferring the memory unit from the defective control unit to the new control unit. After power-up, the drive will scan the memory unit. This can take several minutes. WARNING! Do not remove or insert the memory unit when the control unit is powered.
Page 203: Replacing Safety Functions Modules Fso-12 (Option +Q973) And Fso-21 (Option +Q972)
Maintenance 203 Replacing safety functions modules FSO-12 (option +Q973) and FSO-21 (option +Q972) Do not repair safety functions modules. Replace a faulty module with a new one as described in section Installing the FSO-xx safety functions module (page 143).
Page 205: Ordering Information
This chapter gives ordering information on additional components available from ABB for the drive module installation. Note: This chapter only lists the installation accessories available from ABB. All other parts must be sourced from a third party by the system integrator.
Page 206: Brake Choppers And Resistors
206 Ordering information Type Description Ordering code Illustration ACS-AP-I Control panel 3AUA0000088311 Door mounting kit for flush mounting. Includes a control DPMP-01 panel mounting platform, an 3AUA0000108878 IP54 cover and a 3- meter panel connection cable. Brake choppers and resistors See chapter Resistor braking (page 285).
Page 207 Ordering information 207 Enclosure width / Degree of protec- Kit code Ordering code Illustration tion 800 mm / IP20 A-8-X-023 3AUA0000117005 Instruction code: 3AUA0000116887 800 mm / IP42 A-8-X-026 3AUA0000117009 Instruction code: 3AUA0000116875 800 mm / IP54 A-8-X-029 3AXD50000009186 Instruction code: 3AXD50000010001...
Page 208: Air Outlet Kits
208 Ordering information ￭ Air outlet kits Enclosure width / Degree of protec- Kit code Ordering code Illustration tion 800 mm / IP20 A-4-X-062 3AUA0000125201 Instruction code: 3AXD50000001982 Note: Fan to be ordered separately 800 mm / IP42 A-4-X-060 3AUA0000114967 Instruction code: 3AUA0000115290 Note: Fan to be ordered separately 800 mm / IP54 (IEC)
Page 209: Cooling Fans
Ordering information 209 Enclosure width / Degree of protec- Kit code Ordering code Illustration tion 800 mm / IP54 (UL) A-4-X-067 3AXD50000010362 Instruction code: 3AXD50000010284 Note: Fan to be ordered separately Cooling fans Two cooling fans must be installed inside the air outlet compartment to ensure sufficient cooling of the cabinet.
Page 210: Fso Accessories Kit
210 Ordering information FSO accessories kit Kit code Ordering code Illustration A-X-X-279 3AXD50000025495 Instruction code: 3AXD50000025583 Control panel mounting platforms Ordering code DPMP-02 control panel mounting platform 3AXD50000009374 DPMP-04 control panel mounting platform 3AXD50000217717 Retrofit accessory kits Option code Ordering code Common mode filter kit +E208 3AXD50000026145...
Page 211 Ordering information 211 Option code Ordering code For frame R11: IP20 shrouds for covering the input and 3AXD50000019538 motor cabling area 1) The drive module is delivered with full size cable connection terminals for output power cables as standard. They can be excluded with option +0H371. 2) The drive module is delivered with IP20 shrouds for covering the input and motor cabling area as standard.
Page 213: Technical Data
Technical data 213 Technical data Contents of this chapter This chapter contains the technical specifications of the drive, for example the ratings, sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings. Marine type-approved drives (option +C132) See ACS880-01 /04+C132 marine type-approved drives supplement (3AXD50000010521 [English]) for the ratings, marine-specific data and reference to valid marine type...
Page 214 214 Technical data IEC RATINGS ACS880- Frame Input Output ratings 04-… size current Nominal use Light-duty Heavy-duty I max I max_start I Ld P Ld I Hd P Hd 820A-3 1020 1100 880A-3 1100 1100 725* U n = 500 V 460A-5 503A-5 583A-5...
Page 215 The power ratings apply to most IEC 34 motors at the nominal voltage of the drive. ABB recommends to select the drive, motor and gear combination for the required motion profile with the DriveSize dimensioning tool available from ABB.
Page 216: Output Derating
216 Technical data Output derating ￭ When is derating necessary Derate the continuous output current of the drive if • ambient temperature exceeds +40 °C (+104 °F) or • drive is installed higher than 1000 m (3280 ft) above sea level •...
Page 217: Deratings For Special Settings In The Drive Control Program
Ex motor, sine filter, low noise Table below gives the deratings for these cases: • drive is used with an ABB motor for explosive atmospheres (Ex) and EX motor in parameter 95.15 Special HW settings is enabled • sine filter given in the selection table (see section...
Page 218 218 Technical data • Low noise optimization is selected in parameter 97.09 Switching freq mode. With other than recommended sine filters (see section Sine filters) and non-ABB Ex motors, contact ABB. ACS880- Output ratings for special settings 04-… Ex motor (ABB Ex motor)
Page 219: High Speed Mode
The power ratings apply to most IEC 34 motors at the nominal voltage of the drive. ABB recommends to select the drive, motor and gear combination for the required motion profile with the DriveSize dimensioning tool available from ABB.
Page 220 220 Technical data Deratings with selection High speed mode of parameter 95.15 Special HW settings 120 Hz output frequency Maximum output frequency Light- Heavy- Maxim- Light- Heavy- ACS880- Fre- Nominal use duty duty um fre- Nominal use duty duty 04-… quency quency I Ld...
Page 221: Fuses (Iec)
Fuses (IEC) aR fuses by Cooper Bussmann for protection against short-circuit in the input power cable of the drive are listed below. Ultrarapid (aR) fuses per drive module Fuse Input cur- ACS880-04-… rent Type DIN A 2 s Size 43653...
Page 222 222 Technical data Note: In multicable installations, install only one fuse per phase (not one fuse per conductor). Fuses with higher current rating than the recommended ones must not be used. Fuses with lower current rating can be used. Fuses from other manufacturers can be used if they agree with the ratings and the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table.
Page 223: Fuses (Ul)
Technical data 223 Fuses (UL) UL fuses for branch circuit protection per NEC per drive module are listed below. Obey local regulations. Fuse Fuse Input current ACS880-04-… Manufac- Type turer class U n = 480 V ACS880-04-460A-5 Bussmann JJS-600 ACS880-04-503A-5...
Page 224: Circuit Breakers (Iec)
The protective characteristics of circuit breakers depend on the type, construction and settings of the breakers. There are also limitations pertaining to the short-circuit capacity of the supply network. Your local ABB representative can help you in selecting the breaker type when the supply network characteristics are known.
Page 225: Dimensions, Weights And Free Space Requirements
ACS880-04-721A-7 1) Maximum allowed rated conditional short-circuit current (IEC 61439-1) of the electrical power network 2) Contact your local ABB representative WARNING! Due to the inherent operating principle and construction of circuit breakers, independent of the manufacturer, hot ionized gases can escape from the breaker enclosure in case of a short-circuit.
Page 226 226 Technical data Optional selection +0B051+0H371 (without shrouds and full-size output power cable connection terminals Frame Height Width Depth Weight* size 1462 57.56 12.01 19.92 1662 65.43 12.01 19.92 Optional selection +H381 (full power cabling panels) Frame Height Width Depth Weight* size 1590...
Page 227: Losses, Cooling Data And Noise
Technical data 227 Losses, cooling data and noise Air flow Heat dissipation Noise ACS880-04-… Frame size m 3 /h ft 3 /min dB(A) U n = 400 V ACS880-04-505A-3 1200 5602 ACS880-04-585A-3 1200 6409 ACS880-04-650A-3 1200 8122 ACS880-04-725A-3 1200 8764...
Page 228: Typical Power Cable Sizes
228 Technical data Typical power cable sizes The table below gives copper and aluminum cable types with concentric copper shield for the drive modules with nominal current. See also Terminal and entry data for the power cables (page 229). IEC 1) US 2) ACS880- 04-…...
Page 229: Terminal And Entry Data For The Power Cables
It is possible to use the maximum cable size (4×[3×240] mm or 4 ×[(3×500 MCM]) only with special cable lugs and additional insulation. For more information, contact your local ABB representative. Terminal data for the control cables See section Default I/O diagram of the drive control unit (ZCU-1x) (page 149)
Page 230: Electrical Power Network Specification
ACS880-04-xxxx-3 drives: 380…415 VAC 3-phase +10%…-15%. This is indicated in the type designation label as typical input voltage level 3~400 V AC. ACS880-04-xxxx-5 drives: 380…500 V AC 3-phase +10%…-15%. This is indicated in the type designation label as typical input voltage levels 3~400/480/500 V AC.
Page 231: Brake Resistor Data
Note: Long cables cause a motor voltage decrease which limits the available motor power. The decrease depends on the motor cable length and characteristics. Contact ABB for more information. Note that a sine filter (optional) at the drive output also causes a voltage decrease.
Page 232: Control Panel Type
232 Technical data ACS880-04-… I DC (A) Capacitance (mF) ACS880-04-430A-7 ACS880-04-470A-7 ACS880-04-522A-7 ACS880-04-590A-7 ACS880-04-650A-7 ACS880-04-721A-7 Control panel type ACS-AP-W assistant control panel with Bluetooth connection. Efficiency Approximately 98% at nominal power level. Protection classes for module Degrees of protection IP00 (standard) (IEC/EN 60529) IP20 (with option "IP20 shrouds for covering the input and motor cabling...
Page 233: Ambient Conditions
Technical data 233 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 station- (in the protective (in the protective ary use) package) package) Installation site altitude For TN and TT neutral-...
Page 234: Materials
100 mm (4 in) for weight over 100 kg weight over 100 kg (220 lb) (220 lb) Materials See Recycling instructions and environmental information for ACS880-04, ACS880-04F, ACS880-14, ACS880-34, ACS580-04, ACH580-04, ACH580-34, ACQ580-04 and ACQ580-34 drives (3AXD50000137688 [English]). ￭ Color RAL 9002 ￭...
Page 235 IEC 62635 guidelines. To aid recycling, plastic parts are marked with an appropriate identification code. Contact your local ABB distributor for further information on environmental aspects and recycling instructions for professional recyclers. End of life treatment must follow...
Page 236: Applicable Standards
236 Technical data Applicable standards The drive complies with the following standards. IEC/EN 61800-5- Adjustable speed electrical power drive systems. Part 5-1: Safety require- 1:2007 ments – electrical, thermal and energy EN 60204-1:2006 Safety of machinery. Electrical equipment of machines. Part 1: General +A1:2010 requirements.
Page 237: Emc Compliance (Iec/En 61800-3:2004)
Technical data 237 CSA certification mark for USA and Canada Product has been tested and evaluated against the relevant North American standards by the CSA Group. Valid with rated voltages up to 600 V. EAC (Eurasian Conformity) mark Product complies with the technical regulations of the Eurasian Customs Union. EAC mark is required in Russia, Belarus and Kazakhstan.
Page 238: Category C2
238 Technical data Drive of category C2: drive of rated voltage less than 1000 V and intended to be installed and started up only by a professional when used in the first environment. Note: A professional is a person or organization having necessary skills in installing and/or starting up power drive systems, including their EMC aspects.
Page 239: Category C4
Technical data 239 WARNING! A drive of category C3 is not intended to be used on a low-voltage public network which supplies domestic premises. Radio frequency interference is expected if the drive is used on such a network. ￭ Category C4 The drive complies with the C4 category with these provisions: 1.
Page 240: Compliance With The European Machinery Directive
240 Technical data WARNING! A drive of category C4 is not intended to be used on a low-voltage public network which supplies domestic premises. Radio frequency interference is expected if the drive is used on such a network. Compliance with the European Machinery Directive The drive is an electronic product which is covered by the European Low Voltage Directive.
Page 241: Ul And Csa Checklist
• The drive provides motor overload protection. This feature is not enabled when the drives leaves the ABB factory. For enabling this motor overload protection, see the firmware manual. • The drive overvoltage category according to IEC 60664-1 is III...
Page 242: Disclaimers
ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or...
Page 243: Dimension Drawings
Dimension drawings 243 Dimension drawings Contents of this chapter This chapter contains dimension drawings of the drive modules with optional parts for Rittal VX25 enclosure assembly.
Page 244: R10 - Standard Configuration
244 Dimension drawings R10 – Standard configuration...
Page 245: R10 With Options +E208+H370+J414+P905
Dimension drawings 245 R10 with options +E208+H370+J414+P905...
Page 246: R10 With Options +0B051+C173+E208+H356+0H354+0H371
246 Dimension drawings R10 with options +0B051+C173+E208+H356+0H354+0H371...
Page 247: R10 With Options +0B051+E208+H356+0H371
Dimension drawings 247 R10 with options +0B051+E208+H356+0H371...
Page 248: R10 With Options +E208+H356+H381+J414+P905
248 Dimension drawings R10 with options +E208+H356+H381+J414+P905...
Page 249: R10 - Cabling Panels (+H381) Installed Into A Rittal Vx25 Enclosure
Dimension drawings 249 R10 – Cabling panels (+H381) installed into a Rittal VX25 enclosure...
Page 250: R10 With Options +E208+H370+H391+0J400
250 Dimension drawings R10 with options +E208+H370+H391+0J400...
Page 251: R11 - Standard Configuration
Dimension drawings 251 R11 – Standard configuration...
Page 252: R11 With Options +E208+H370+J414+P905
252 Dimension drawings R11 with options +E208+H370+J414+P905...
Page 253: R11 With Options +0B051+E208+H356+0H371
Dimension drawings 253 R11 with options +0B051+E208+H356+0H371...
Page 254: R11 With Options +E208+H356+H381+J414+P905
254 Dimension drawings R11 with options +E208+H356+H381+J414+P905...
Page 255: R11 With Options +0B051+C173+E208+H356+0H354+0H371
Dimension drawings 255 R11 with options +0B051+C173+E208+H356+0H354+0H371...
Page 256: R11 - Cabling Panels (+H381) Installed Into A Rittal Vx25 Enclosure
256 Dimension drawings R11 – Cabling panels (+H381) installed into a Rittal VX25 enclosure...
Page 257: Bottom Plate For Option +H381 In Rittal Vx25 400 Mm Wide Enclosure Installation
Dimension drawings 257 Bottom plate for option +H381 in Rittal VX25 400 mm wide enclosure installation Note: The bottom plate is not an ABB part. 3AXD50000433988 Insert nut PEM-S-M8-2 or equal (2 pcs) Cable entry area...
Page 258: Frame R11 With Options +E208+H370+H391+0J400
258 Dimension drawings Frame R11 with options +E208+H370+H391+0J400...
Page 259: Air Baffles For The Standard Drive Module And Option +C173
Dimension drawings 259 Air baffles for the standard drive module and option +C173 This drawing shows the dimensions of the hole in the air baffle around the standard drive module and flat mounting option +C173. The drawing also shows the correct vertical location area of the air baffle as measured from the top grill.
Page 260: Air Baffles For Option +H381 In Rittal Vx25 400 Mm Wide Enclosure Installation
260 Dimension drawings Air baffles for option +H381 in Rittal VX25 400 mm wide enclosure installation Note: These air baffles are not ABB parts.
Page 261: Material Of The Air Baffles
Dimension drawings 261 ￭ Material of the air baffles 0.75 mm polycabonate (PC) film LEXAN® FR60 (GE) with UL94 V–0 listing, UV stability. Unmarked bend radii 0.6 mm. External control unit 3AXD50000011687...
Page 263: Example Circuit Diagram 263
Example circuit diagram 263 Example circuit diagram Contents of this chapter This chapter shows an example circuit diagram for a cabinet-installed drive module.
Page 264: 264 Example Circuit Diagram
264 Example circuit diagram Example circuit diagram This diagram is an example for the main wiring of a drive cabinet. Note that the diagram includes components which are not included in a basic delivery (* plus code options, **other options, ***to be acquired by the customer). V20 V10 SOIA BGDR...
Page 265 Example circuit diagram 265 360 degree grounding recommended **Brake resistor...
Page 267: The Safe Torque Off Function
The Safe torque off function 267 The Safe torque off function Contents of this chapter This chapter describes the Safe torque off (STO) function of the drive and gives instructions for its use. Description WARNING! In case of parallel-connected drives or dual-winding motors, the STO must be activated on each drive to remove the torque from the motor.
Page 268: Compliance With The European Machinery Directive
268 The Safe torque off function Standard Name IEC 60204-1:2016 Safety of machinery – Electrical equipment of machines – Part 1: EN 60204-1:2018 General requirements IEC 61000-6-7:2014 Electromagnetic compatibility (EMC) – Part 6-7: Generic stand- ards – Immunity requirements for equipment intended to perform functions in a safety-related system (functional safety) in indus- trial locations IEC 61326-3-1:2017...
Page 269: Wiring
The Safe torque off function 269 Wiring For the electrical specifications of the STO connection, see the technical data of the control unit. ￭ Activation switch In the wiring diagrams, the activation switch has the designation [K]. This represents a component such as a manually operated switch, an emergency stop push button switch, or the contacts of a safety relay or safety PLC.
Page 270: Single Drive (Internal Power Supply)
270 The Safe torque off function ￭ Single drive (internal power supply) Dual-channel connection +24 V SGND UDC+ UDC– Drive Control unit Control logic To motor Activation switch...
Page 271: Single-Channel Connection
The Safe torque off function 271 Single-channel connection +24 V SGND Note: • Both STO inputs (IN1, IN2) must be connected to the activation switch. Otherwise, no SIL/PL classification is given. • Pay special attention to avoiding any potential failure modes for the wiring. For example, use shielded cable.
Page 272: Multiple Drives
272 The Safe torque off function ￭ Multiple drives Internal power supply XSTO +24 V SGND XSTO SGND XSTO SGND Drive Control unit Activation switch...
Page 273: External Power Supply
The Safe torque off function 273 External power supply 24 V DC – XSTO +24 V SGND XSTO SGND XSTO SGND Drive Control unit Activation switch...
Page 274: Operation Principle
274 The Safe torque off function Operation principle 1. The Safe torque off activates (the activation switch is opened, or safety relay contacts open). 2. The STO inputs of the drive control unit de-energize. 3. The control unit cuts off the control voltage from the output IGBTs. 4.
Page 275: Start-Up Including Validation Test
The Safe torque off function 275 Start-up including validation test To ensure the safe operation of a safety function, validation is required. The final assembler of the machine must validate the function by performing a validation test. The test must be performed •...
Page 276 276 The Safe torque off function Action Test the operation of the STO function when the motor is stopped. • Give a stop command for the drive (if running) and wait until the motor shaft is at a standstill. Make sure that the drive operates as follows: •...
Page 277: Use
The Safe torque off function 277 1. Open the activation switch, or activate the safety functionality that is wired to the STO connection. 2. The STO inputs on the drive control unit de-energize, and the control unit cuts off the control voltage from the output IGBTs. 3.
Page 278 278 The Safe torque off function • The Safe torque off function overrides all other functions of the drive. • The Safe torque off function is ineffective against deliberate sabotage or misuse. • The Safe torque off function has been designed to reduce the recognized hazardous conditions.
Page 279: Maintenance
If any wiring or component change is needed after start up, or the parameters are restored, do the test given in section Validation test procedure (page 275). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. ￭ Competence...
Page 280: Fault Tracing
See the firmware manual of the drive control program for the indications generated by the drive, and for details on directing fault and warning indications to an output on the control unit for external diagnostics. Any failures of the Safe torque off function must be reported to ABB.
Page 281: Safety Data
The Safe torque off function 281 Safety data The safety data for the Safe torque off function is given below. Note: The safety data is calculated for redundant use, and does not apply if both STO channels are not used. PFD avg PFD avg Frame...
Page 282: Abbreviations
282 The Safe torque off function • STO warning indication (parameter 31.22) delay: < 1000 ms ￭ Abbreviations Abbr. Reference Description Cat. EN ISO 13849-1 Classification of the safety-related parts of a control system in respect of their resistance to faults and their subsequent behavior in the fault condition, and which is achieved by the structural arrangement of the parts, fault detection and/or by their reliability.
Page 283: Tüv Certificate
The Safe torque off function 283 ￭ TÜV certificate The TÜV certificate is available on the Internet at www.abb.com/drives/documents.
Page 284: Declaration Of Conformity
284 The Safe torque off function ￭ Declaration of conformity...
Page 285: Contents Of This Chapter
Resistor braking 285 Resistor braking Contents of this chapter This chapter describes how to select, protect and wire brake choppers and resistors. The chapter also contains the technical data. When is resistor braking necessary? Resistor braking is necessary for high capacity braking if a regenerative drive cannot be used.
Page 286: Resistor Cables
IGBT semiconductors of the brake chopper. Note: ABB has not verified that the EMC requirements are fulfilled with custom brake resistors and cabling. The customer must consider the EMC compliance of the complete installation.
Page 287: Protecting The System Against Thermal Overload
The drive will disable power flow through the input bridge if the chopper remains conductive in a fault situation but the charging resistor may fail. Note: If an external brake chopper (outside the drive module) is used, ABB always requires a main contactor.
Page 288: Calculation Example
) of the internal brcont brake chopper = 315 kW. Preselected ABB resistor = 2×SAFUR200F50. Braking power of the motor is 300 kW. The duration of a braking cycle (T) is three minutes -> number of braking pulses in 400 seconds = 2.2. The braking time (t ) is 20 seconds.
Page 289: Mechanical Installation Of Resistors
Resistor braking 289 2. make sure that the resistance of the custom resistor does not restrict the braking capability needed, ie. where P max Maximum power generated by the motor during braking U DC Drive intermediate DC circuit voltage. 1.35 · 1.2 · 415 V DC (when supply voltage is 380 to 415 V AC) 1.35 ·...
Page 290: Electrical Installation
290 Resistor braking Electrical installation ￭ Measuring the insulation of the assembly Obey the instructions given in section Measuring the insulation of the brake resistor circuit (page 125). ￭ Connection diagram See section Power cable connection diagram (page 127). ￭ Connection procedure •...
Page 291: Technical Data
Resistor braking 291 Set parameter 31.02 External event 1 type to Fault. Set parameter 43.07 Brake chopper run enable to Other [bit] and select from parameter 10.01 DI status the digital input where the thermal switch of the brake resistor is wired. Set the resistance value of the resistor to parameter 43.10 Brake resistance.
Page 292: Safur Resistors
292 Resistor braking Internal brake chopper Example brake resistor(s) ACS880- P brcont R min P Rcont 04-… Type 880A-5 3×SAFUR200F500 16200 U n = 690 V 330A-7 SAFUR200F500 3600 370A-7 SAFUR200F500 3600 430A-7 SAFUR200F500 3600 470A-7 2×SAFUR125F500 7200 522A-7 2×SAFUR125F500 7200 590A-7 2×SAFUR125F500...
Page 293: Dimensions, Weights And Ordering Codes
Resistor braking 293 Dimensions, weights and ordering codes 5 5 Ø 7 Brake resistor type Weight ABB ordering code SAFUR125F500 25 kg (55 lb) 68759285 SAFUR200F500 30 kg (66 b) 68759340 ￭ Terminals and cable entry data See section Terminal and entry data for the power cables (page...
Page 295: Filters
￭ When is a du/dt filter necessary? Examining the compatibility of the motor and drive (page 96). ￭ Selection table du/dt filter types for the drive modules are given below. ACS880-04-… du/dt filter ACS880-04-… du/dt filter ACS880-04-… du/dt filter type...
Page 296: Ordering Codes
296 Filters ￭ Ordering codes Filter type ABB ordering code FOCH0610-70 68550505 FOCH0875-70 3AUA0000129544 ￭ Description, installation and technical data of the FOCH filters See FOCH du/dt filters hardware manual (3AFE68577519 [English]). Sine filters ￭ When is a sine filter necessary? Examining the compatibility of the motor and drive (page 96).
Page 297: Derating
Filters 297 ￭ Derating See section Deratings for special settings in the drive control program (page 217). ￭ Description, installation and technical data of the sine filters See Sine filters hardware manual (3AXD50000016814 [English]). For more information, contact ABB.
Page 299 23. Step-by-step drawings for an installation example of standard drive configuration with option +E208 in Rittal VX25 600 mm wide enclosure...
Page 300 Tapping screw M6×12 Torx Combi screw M8×30 (Hex) Tapping screw M6×12 Torx Rittal 8617.030 T30 (Hex) 9 N·m (80 lbf·in) T30 (Hex) 9 N·m (80 lbf·in) 20 N·m (14.75 lbf·ft) Combi screw M4×8 Torx Rittal 8606.000 T20 2 N·m (18 lbf·in) M6x20 Torx T25 8 N·m (71 lbf·in) Combi screw M8×30 Hex 20 N·m (14.75 lbf·ft) Rittal 4396.500...
Page 301 Combi screw M12×25 Hex 70 N·m (52 lbf·ft) Combi screw M8×16 Hex Hex nut M12 70 N·m (52 lbf·ft) Combi screw M6×12 Torx T25 20 N·m (14.75 lbf·ft) Combi screw M12×25 Hex Washer M12 or equal 8 N·m (71 lbf·in) 20 N·m (14.75 lbf·ft) Hex screw M12×35 full thread 70 N·m (52 lbf·ft)
Page 302 Hex nut M12 70 N·m Washer M12 or equal Hex screw M12×35 full thread 70 N·m Washer M12 or equal Combi screw M4×10 Torx T20 2 N·m Combi screw M6×20 Combi screw M6×20 Torx T25 2 N·m Torx T25 2 N·m Combi screw M4×10 Torx T20 2 N·m Combi screw M6×20...
Page 303 Note: These air baffles are compatible with option +B051 only. For the standard drive module configuration see section Standard drive module configuration.
Page 305 24. Step-by-step drawings for installing full cabling panels (option +H381) in a Rittal 400 mm wide enclosure 3AXD50000439317...
Page 306 ABB parts Pedestal guide plate Top guide plate Customer-made parts (not ABB or Rittal product) Air baffles Installation procedure 1. Install three Rittal support rails (4396.500) on the bottom of the enclosure 2. Install the pedestal guide onto the support rails 3.
Page 307 3AXD50000439317...
Page 308 Installation procedure (continued) 7. Install the output cabling panel 8. Install the side guides to the output cabling panel (2 screws for each side guide) 9. Attach the grounding busbar to the input cabling panel. Back view is shown above. 10.
Page 309 3AXD50000439317...
Page 311 25. Step-by-step drawings for a flat installation example in a Rittal 600 mm wide enclosure 3AXD50000440559...
Page 313 26. Step-by-step drawings for option +H391 installation example in a Rittal 600 mm wide enclosure ABB parts for option +H391 Support for back top mounting bracket Handle Bottom mounting bracket ABB standard parts Lowest back cover plate Back top mounting bracket...
Page 315 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.

ABB ACS880-04 Hardware Manual

1 Safety Instructions

2 Introduction to the Manual

21 Resistor Braking

3 Operation Principle and Hardware Description

4 Generic Cabinet Planning Instructions

5 Guidelines for Planning the Mechanical Installation

6 Mechanical Installation

7 Guidelines for Planning the Electrical Installation

8 Electrical Installation

9 Control Unit

10 Installation Example of the Standard Drive Module Configuration

11 Installation Example with Full Cabling Panels (Option +H381)

12 Installation Checklist

13 Start-Up

14 Fault Tracing

15 Maintenance

16 Ordering Information

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Summary of Contents for ABB ACS880-04