Page 1 ABB industrial drives Hardware manual ACS880-01 drives (0.55 to 250 kW, 0.75 to 350 hp)
Page 2: List Of Related Manuals
Drive hardware manuals and guides Code (English) ACS880-01 hardware manual 3AUA0000078093 ACS880-01 quick installation guide for frames R1 to R3 3AUA0000085966 ACS880-01 quick installation guide for frames R4 and R5 3AUA0000099663 ACS880-01 quick installation guide for frames R6 to R9...
Page 3 Hardware manual ACS880-01 drives (0.55 to 250 kW, 0.75 to 350 hp) Table of contents Safety instructions Mechanical installation Electrical installation Start-up © 2013 ABB Oy. All Rights Reserved. 3AUA0000078093 Rev G EFFECTIVE: 2013-07-01...
Page 5: Table Of Contents
Table of contents List of related manuals ............2 1.
Page 6 AM_ ............58 Additional requirements for ABB high-output and IP23 motors ....59 Additional requirements for non-ABB high-output and IP23 motors .
Page 7 Implementing thermal overload and short-circuit protection ......71 Protecting the drive and input power cable in short-circuits ..... . . 71 Protecting the motor and motor cable in short-circuits .
Page 8 ACS880-01-xxxx-07 ........
Page 9 11. Technical data What this chapter contains ..........137 Ratings .
Page 10 12. Dimension drawings What this chapter contains ..........177 Frame R1 (IP21, UL Type 1) .
Page 11 Providing feedback on ABB Drives manuals ........
Page 13: Safety Instructions
Safety instructions 13 Safety instructions What this chapter contains This chapter contains the safety instructions which you must follow when installing, operating and servicing the drive. If ignored, physical injury or death may follow, or damage may occur to the drive, motor or driven equipment. Read the safety instructions before you work on the unit.
Page 14: Safety In Installation And Maintenance
14 Safety instructions Safety in installation and maintenance Electrical safety These warnings are intended for all who work on the drive, motor cable or motor. WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment: •...
Page 15: Grounding
Safety instructions 15 Grounding These instructions are intended for all who are responsible for the grounding of the drive. WARNING! Ignoring the following instructions can cause physical injury, death, increased electromagnetic interference and equipment malfunction: • Ground the drive, motor and adjoining equipment to ensure personnel safety in all circumstances, and to reduce electromagnetic emission and interference.
Page 16: Permanent Magnet Motor Drives
16 Safety instructions Permanent magnet motor drives These are additional warnings concerning permanent magnet motor drives. WARNING! Ignoring the instructions can cause physical injury or death, or damage to the equipment: • Do not work on the drive when the permanent magnet motor is rotating. Also, when the supply power is switched off and the inverter is stopped, a rotating permanent magnet motor feeds power to the intermediate circuit of the drive and the supply connections become live.
Page 17: General Safety
Safety instructions 17 General safety These instructions are intended for all who install and service the drive. WARNING! Ignoring the following instructions can cause physical injury or death, or damage to the equipment: • Handle the unit carefully. • Frame sizes R6 to R9: Lift the drive using the lifting eyes of the unit. Do not tilt the drive.
Page 18: Printed Circuit Boards
18 Safety instructions Printed circuit boards WARNING! Ignoring the following instructions can cause damage to the printed circuit boards: • Wear a grounding wrist band when handling the boards. Do not touch the boards unnecessarily. The printed circuit boards contain components sensitive to electrostatic discharge.
Page 19: Permanent Magnet Motor Drives
Safety instructions 19 Permanent magnet motor drives WARNING! Do not run the motor over the rated speed. Motor overspeed leads to overvoltage which may damage or explode the capacitors in the intermediate circuit of the drive.
Page 20 20 Safety instructions...
Page 21: Introduction To The Manual
Introduction to the manual 21 Introduction to the manual What this chapter contains This chapter describes the manual. It contains a flowchart of steps for checking the delivery, installing and starting up the drive. The flowchart refers to chapters/sections in this manual and to other manuals. Target audience This manual is intended for people who plan the installation, install, start-up, use and service the drive.
Page 22: Related Manuals
22 Introduction to the manual Electrical installation gives instructions on wiring the drive. Installation checklist contains a list for checking the mechanical and electrical installation of the drive. Start-up describes the start-up procedure of the drive. Fault tracing describes the fault tracing of the drive. Maintenance contains preventive maintenance instructions.
Page 23: Quick Installation, Start-Up And Operating Flowchart
Introduction to the manual 23 Quick installation, start-up and operating flowchart Task Plan the electrical installation and acquire the Planning the electrical installation accessories needed (cables, fuses, etc.). (page 53) Check the ratings, required cooling air flow, input Technical data (page 137) power connection, compatibility of the motor, motor connection, and other technical data.
Page 24: Terms And Abbreviations
24 Introduction to the manual Terms and abbreviations Term/ Explanation Abbreviation Electromagnetic compatibility Electromagnetic interference Electrical metallic tubing FIO-01 Optional digital I/O extension module FIO-11 Optional analog I/O extension module FCAN-01 Optional FCAN-01 CANopen adapter module FCNA-01 Optional ControlNet™ adapter module FDNA-01 Optional DeviceNet™...
Page 25: Safety Data (Sil, Pl)
Introduction to the manual 25 Term/ Explanation Abbreviation Safely-limited speed without encoder Safe speed 1 Safe stop emergency Safe minimum speed Safe torque off Safety data (SIL, PL) Abbr. Reference Description EN/ISO 13849-1 Common cause failure (%) EN/ISO 13849-1 Diagnostic coverage IEC 61508 Failure In time: 1E-9 hours IEC 61508...
Page 26 26 Introduction to the manual...
Page 27: Operation Principle And Hardware Description
Operation principle and hardware description What this chapter contains This chapter briefly describes the operation principle and construction of the drive. Product overview The ACS880-01 is a drive for controlling asynchronous AC induction motors, permanent magnet synchronous motors and AC induction servomotors.
Page 28: Main Circuit
28 Operation principle and hardware description Main circuit The main circuit of the drive is shown below. ACS880-01 T1/U T2/V T3/W R- UDC+ UDC- Rectifier. Converts alternating current and voltage to direct current and voltage. DC link. DC circuit between rectifier and inverter.
Page 29: Layout (Ip21, Ul Type 1)
Operation principle and hardware description 29 Layout (IP21, UL Type 1) The components of the standard IP21 drive are shown below (view of frame R5). Control panel Front cover Cable entry box Four fastening points at the back of the unit Heatsink Lifting holes...
Page 30: Layout (Ip55)
30 Operation principle and hardware description Layout (IP55) The components of the IP55 drive (option +B056) are shown below (view of frame R4). Control panel behind the control panel cover Front cover Four fastening points at the back of the unit Heatsink Lifting holes...
Page 31: Layout (Ul Type 12)
Operation principle and hardware description 31 Layout (UL Type 12) The components of the UL Type 12 drive (option +B056) are shown below (view of frame R6). Control panel behind the control panel cover Front cover Four fastening points at the back of the drive Heatsink Lifting holes...
Page 32: Overview Of Power And Control Connections
32 Operation principle and hardware description Overview of power and control connections The diagram shows the power connections and control interfaces of the drive. Slot 1 X208 Slot 2 Slot 3 U/T1 V/T2 W/T3 UDC+ UDC- Option modules can be inserted into slots 1, 2 and 3 as follows: Modules Into slots Analog and digital I/O extension modules except FDIO...
Page 33: External Control Connection Terminals
Operation principle and hardware description 33 External control connection terminals The layout of external control connection terminals of the drive is shown below. Description XPOW External power input Analog inputs X202 Analog outputs XD2D Drive-to-drive link X208 XRO1 Relay output 1 XRO2 Relay output 2 X205...
Page 34: Control Panel
34 Operation principle and hardware description Control panel The control panel can be removed by pulling it forward from the top edge and reinstalled in reverse order. For the use of the control panel, see the firmware manual or ACS-AP assistant control panels user’s manual (3AUA0000085685 [English]). Type designation label The type designation label includes an IEC and NEMA rating, appropriate markings, a type designation and a serial number, which allow identification of each unit.
Page 35: Type Designation Key
Type designation key The type designation contains information on the specifications and configuration of the drive. The first digits from left express the basic configuration, eg, ACS880-01- 12A6-3 The optional selections are given thereafter, separated by plus signs, eg, +L519. The main selections are described below. Not all selections are available for all types.
Page 36 36 Operation principle and hardware description CODE DESCRIPTION K458 FSCA-01 RS-485 adapter module K462 FCNA-01 ControlNet™ adapter module K469 FECA-01 EtherCAT adapter module K470 FEPL-01 Ethernet POWERLINK adapter module K473 FENA-11 high performance Ethernet/IP™, Modbus/TCP and PROFINET adapter module I/O extensions and feedback interfaces L500 FIO-11 analog I/O extension module L501...
Page 37 Operation principle and hardware description 37 CODE DESCRIPTION R713 Polish R714 Turkish...
Page 38 38 Operation principle and hardware description...
Page 39: Mechanical Installation
Mechanical installation 39 Mechanical installation What this chapter contains This chapter gives a description of the mechanical installation of the drive. Safety WARNING! For frame sizes R6 to R9: Use the lifting eyes of the drive when you lift the drive. Do not tilt the drive. The drive is heavy and its center of gravity is high.
Page 40: Examining The Installation Site
40 Mechanical installation Examining the installation site The drive must be installed in an upright position with the cooling section against a wall. All IP21 (UL Type 1) and IP55 drives and UL Type 12 drives of frames R1 to R3 can be installed tightly side by side.
Page 41: Moving The Drive
Mechanical installation 41 Moving the drive Move the transport package by pallet truck to the installation site. Upacking and examining the delivery (frames R1 to R5) This illustration shows the layout of the transport package. Examine that all items are present and there are no signs of damage.
Page 42: Frame R5 Cable Entry Box (Ip21, Ul Type 1)
42 Mechanical installation To unpack: • Cut the straps (10). • Remove the top cardboard cover (11) and cushions (6…9). • Lift the cardboard sleeve (5). • Lift the drive. Frame R5 cable entry box (IP21, UL Type 1) This illustration shows the contents of the cable entry box package. The package also includes an assembly drawing which shows how to install the cable entry box to the drive module frame.
Page 43: Upacking And Examining The Delivery (Frames R6 To R9)
Mechanical installation 43 Upacking and examining the delivery (frames R6 to R9) This illustration shows the layout of the transport package. Examine that all items are present and there are no signs of damage. Read the data on the type designation label of the drive to make sure that the drive is of the correct type.
Page 44: Frame R6 Cable Entry Box (Ip21, Ul Type 1)
44 Mechanical installation To unpack: • Cut the straps (6). • Remove the top cardboard cover (3) and cushion (4). • Lift the cardboard sleeve (5). • Attach lifting hooks to the lifting eyes of the drive. Lift the drive with a hoist. Frame R6 cable entry box (IP21, UL Type 1) This illustration shows the contents of the cable entry box package.
Page 45: Frame R7 Cable Entry Box (Ip21, Ul Type 1)
Mechanical installation 45 Frame R7 cable entry box (IP21, UL Type 1) This illustration shows the contents of the cable entry box package. The package also includes an assembly drawing which shows how to install the cable entry box to the drive module frame.
Page 46: Frame R8 Cable Entry Box (Ip21, Ul Type 1)
46 Mechanical installation Frame R8 cable entry box (IP21, UL Type 1) This illustration shows the contents of the cable entry box package. There is also an assembly drawing which shows how to install the cable entry box to the drive module frame.
Page 47: Frame R9 Cable Entry Box (Ip21, Ul Type 1)
Mechanical installation 47 Frame R9 cable entry box (IP21, UL Type 1) This illustration shows the contents of the cable entry box package. The package also includes an assembly drawing which shows how to install the cable entry box to the drive module frame.
Page 48: Installing The Drive
48 Mechanical installation Installing the drive These instructions are for drives without vibration dampers. For drives with vibration dampers (option +C131), see the additional instructions (included with the dampers and on the manuals CD). Frames R1 to R4 1. See the dimensions in chapter Dimension drawings.
Page 49: Frames R4 And R7 (Ul Type 12)
Mechanical installation 49 Frames R4 and R7 (UL Type 12) 1. Position the drive onto the screws on the wall as shown in section Frames R5 to R9 without vibration dampers on page 50. 2. Put the hood onto the upper screws. 3.
Page 50: Frames R5 To R9 Without Vibration Dampers
50 Mechanical installation Frames R5 to R9 without vibration dampers 1. See the dimensions in chapter Dimension drawings. Mark the locations for the four or six mounting holes. 2. Drill the mounting holes. 3. Start the screws or bolts into the mounting holes. 4.
Page 51 Mechanical installation 51 200 mm (7.87”) Screw size 300 mm (11.81”)
Page 52: Cabinet Installation
52 Mechanical installation Cabinet installation See ACS880-01 cabinet installation supplement (3AUA0000145446 [English]).
Page 53: Planning The Electrical Installation
Limitation of liability The installation must always be designed and made according to applicable local laws and regulations. ABB does not assume any liability whatsoever for any installation which breaches the local laws and/or other regulations. Furthermore, if the recommendations given by ABB are not followed, the drive may experience problems that the warranty does not cover.
Page 54: European Union
54 Planning the electrical installation European Union To meet the European Union Directives, according to standard EN 60204-1, Safety of Machinery, the disconnecting device must be one of the following types: • switch-disconnector of utilization category AC-23B (EN 60947-3) • disconnector that has an auxiliary contact that in all cases causes switching devices to break the load circuit before the opening of the main contacts of the disconnector (EN 60947-3) •...
Page 55: Protecting The Motor Insulation And Bearings
Planning the electrical installation 55 Protecting the motor insulation and bearings The drive employs modern IGBT inverter technology. Regardless of frequency, the drive output comprises pulses of approximately the drive DC bus voltage with a very short rise time. The pulse voltage can almost double at the motor terminals, depending on the attenuation and reflection properties of the motor cable and the terminals.
Page 56 56 Planning the electrical installation Motor Nominal AC supply Requirement for type voltage Motor ABB du/dt and common mode filters, insulation insulated N-end motor bearings system < 100 kW 100 kW < P < 350 kW and frame size < IEC 315 IEC 315 <...
Page 57 Planning the electrical installation 57 Motor Nominal AC supply Requirement for type voltage Motor ABB du/dt and common mode filters, insulation insulated N-end motor bearings system < 100 kW 100 kW < P < 350 kW and frame size < IEC 315 IEC 315 <...
Page 58: And Am
Motor nominal power du/dt du/dt filter at the output of the drive. Available from ABB as an optional add-on kit. Common mode filter. Depending on the drive type, CMF is available from ABB as an optional add-on kit. N-end bearing: insulated motor non-drive end bearing n.a.
Page 59: Additional Requirements For Abb High-Output And Ip23 Motors
Additional requirements for 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). This table shows the requirements for ABB random-wound motor series (for example, M3AA, M3AP and M3BP).
Page 60: Additional Requirements For Non-Abb High-Output And Ip23 Motors
60 Planning the electrical installation 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). The table below shows the requirements for random-wound and form-wound non-ABB motors.
Page 61: Additional Data For Calculating The Rise Time And The Peak Line-To-Line Voltage
Planning the electrical installation 61 Additional data for calculating the rise time and the peak line-to-line voltage If you need to calculate the actual peak voltage and voltage rise time considering the actual cable length, proceed as follows: • Peak line-to line voltage: Read the relative Û value from the appropriate diagram below and multiply it by the nominal supply voltage (U •...
Page 62 62 Planning the electrical installation Û du/dt ------------ - (1/μs) l (m) du/dt ------------ - (1/μs) Û l (m) Drive with du/dt filter Drive without du/dt filter Motor cable length Û Relative peak line-to-line voltage (du/dt)/U Relative du/dt value Note: ÛLL and du/dt values are approximately 20% higher with resistor braking.
Page 63: Additional Note For Sine Filters
Planning the electrical installation 63 Additional note for sine filters Sine filters protect the motor insulation system. Therefore, du/dt filter can be replaced with a sine filter. The peak phase-to-phase voltage with the sine filter is approximately 1.5 · U Selecting the power cables General rules Select the input power and motor cables according to local regulations:...
Page 64: Typical Power Cable Sizes
64 Planning the electrical installation Cross-sectional area of the phase Minimum cross-sectional area of the conductors corresponding protective conductor S (mm S < 16 16 < S < 35 35 < S Typical power cable sizes The table below gives copper and aluminum cable types with concentric copper shield for the drives with nominal current.
Page 65 Planning the electrical installation 65 Drive type Frame size ACS880- Cu cable type Al cable Cu cable type Al cable type type AWG/kcmil AWG/kcmil 032A-3 3×10 038A-3 3×10 045A-3 3×16 3×35 061A-3 3×25 3×35 072A-3 3×35 3×50 087A-3 3×35 3×70 105A-3 3×50 3×70...
Page 66: Alternative Power Cable Types
66 Planning the electrical installation Drive type Frame size ACS880- Cu cable type Al cable Cu cable type Al cable type type AWG/kcmil AWG/kcmil 414A-5 2 × (3×150) 2 × (3×240) 2 × 250 MCM = 525…690 V 07A3-7 3×1.5 09A8-7 3×1.5 14A2-7...
Page 67: Recommended Power Cable Types
Planning the electrical installation 67 Recommended power cable types Symmetrical shielded cable with three phase conductors and a concentric PE conductor as shield. The shield must meet the requirements of IEC 61439-1, see page 63. Check with local / state / country electrical codes for allowance. Symmetrical shielded cable with three phase conductors and a concentric PE conductor as shield.
Page 68: Motor Cable Shield
68 Planning the electrical installation Motor cable shield If the motor cable shield is used as the sole protective earth conductor of the motor, ensure that the conductivity of the shield is sufficient. See subsection General rules above, or IEC 61439-1. To effectively suppress radiated and conducted radio- frequency emissions, the cable shield conductivity must be at least 1/10 of the phase conductor conductivity.
Page 69: Armored Cable / Shielded Power Cable
Relay-controlled signals, providing their voltage does not exceed 48 V, can be run in the same cables as digital input signals. The relay-controlled signals should be run as twisted pairs. Relay cable type The cable type with braided metallic screen (for example ÖLFLEX by LAPPKABEL, Germany) has been tested and approved by ABB.
Page 70: Control Panel Cable Length And Type
70 Planning the electrical installation Control panel cable length and type In remote use, the cable connecting the control panel to the drive must not exceed three meters (10 ft). Cable type: shielded CAT 5e or better Ethernet patch cable with RJ-45 ends.
Page 71: Separate Control Cable Ducts
Planning the electrical installation 71 Separate control cable ducts Lead 24 V and 230 V (120 V) control cables in separate ducts unless the 24 V cable is insulated for 230 V (120 V) or insulated with an insulation sleeving for 230 V (120 V).
Page 72: Protecting The Motor And Motor Cable In Short-Circuits
Note: Circuit breakers must not be used without fuses. For more information, contact ABB. Protecting the motor and motor cable in short-circuits The drive protects the motor cable and motor in a short-circuit situation when the motor cable is sized according to the nominal current of the drive.
Page 73: Protecting The Drive Against Ground Faults
Planning the electrical installation 73 Protecting the drive against ground faults The drive is equipped with an internal ground fault protective function to protect the unit against ground faults in the motor and motor cable. This is not a personnel safety or a fire protection feature.
Page 74: Implementing The Power-Loss Ride-Through Function
74 Planning the electrical installation Implementing the Power-loss ride-through function Implement the power-loss ride-through function as follows: • Check that the power-loss ride-through function of the drive is enabled with parameter 30.31 Undervoltage control in the ACS880 primary control program. •...
Page 75: Implementing A Bypass Connection
Planning the electrical installation 75 When you have selected to use DTC motor control mode and motor ramp stop, open the contactor as follows: 1. Give a stop command to the drive. 2. Wait until the drive decelerates the motor to zero speed. 3.
Page 76: Example Bypass Connection
76 Planning the electrical installation Example bypass connection An example bypass connection is shown below. Drive main switch Drive main contactor on/off control Bypass circuit breaker Motor power supply selection (drive or direct-on-line) Drive main contactor Start when motor is connected direct-on- line Bypass contactor Stop when motor is connected direct-on-...
Page 77: Switching The Motor Power Supply From Drive To Direct-On-Line
Planning the electrical installation 77 Switching the motor power supply from drive to direct-on-line 1. Stop the drive and the motor with the drive control panel (drive in local control mode) or with the external stop signal (drive in remote control mode). 2.
Page 78 78 Planning the electrical installation 230 V AC 230 V AC + 24 V DC 1) Relay outputs; 2) Varistor; 3) RC filter; 4) diode...
Page 79: Connecting A Motor Temperature Sensor To The Drive I/O
Planning the electrical installation 79 Connecting a motor temperature sensor to the drive I/O WARNING! IEC 60664 requires double or reinforced insulation between live parts and the surface of accessible parts of electrical equipment which are either non-conductive or conductive but not connected to the protective earth. To fulfill this requirement, the connection of a thermistor (and other similar components) to the digital inputs of the drive can be implemented in three alternate ways:...
Page 80 80 Planning the electrical installation...
Page 81: Electrical Installation
Electrical installation 81 Electrical installation What this chapter contains This chapter gives instructions on wiring the drive. Warnings WARNING! Only qualified electricians are allowed to carry out the work described in this chapter. Follow the Safety instructions in the first chapter of this manual.
Page 82: Motor And Motor Cable
Protective Earth conductor using a measuring voltage of 1000 V DC. The insulation resistance of an ABB motor must exceed 100 Mohm (reference value at 25 °C or 77 °F). For the insulation resistance of other motors, please consult the manufacturer’s instructions.
Page 83: Checking The Compatibility With It (Ungrounded) Systems
Undo the two screws which are marked with EMC AC and EMC DC on the skeleton. See EMC filter disconnecting instructions for ACS880-01 drives with filters +E200 and +E202 (3AUA0000125152 [English]). For frame R4, contact ABB.
Page 84: Connecting The Power Cables
84 Electrical installation Connecting the power cables Connection diagram ACS880-01 UDC+ T1/U T2/V T3/W UDC- (PE) (PE) 3 ~ M For alternatives, see section Selecting the supply disconnecting device on page Use a separate grounding PE cable (2a) or a cable with a separate PE conductor (2b) if the conductivity of the shield does not meet the requirements for the PE conductor (see page 63).
Page 85: Connection Procedure For Frames R1 To R3
Electrical installation 85 Connection procedure for frames R1 to R3 1. Undo the mounting screws at the sides of the front cover. 2. Remove the cover by sliding it forward. 3. Attach the residual voltage warning sticker in the local language to the control panel mounting platform.
Page 86 86 Electrical installation IP55 IP21...
Page 87 Electrical installation 87 L1, L2, L3, T1/U, T2/V, T3/W, R-, R+/UDC+, UDC (N·m) (N·m)
Page 88: Connection Procedure For Frames R4 And R5
88 Electrical installation Connection procedure for frames R4 and R5 1. Remove the front cover. IP21 units: Release the retaining clip with a screwdriver (a) and lift the cover from the bottom outwards (b). 2. For IP21 drives: Remove the cable entry box cover by undoing the mounting screw.
Page 89 Electrical installation 89 11. Install the EMC shroud separating the input and output cabling if not installed yet. 12. Units with option +D150: Slide the brake resistor cable through the brake resistor and control cable clamp assembly. Connect the conductors to the R+ and R- terminals and tighten to the torque given in the figure.
Page 90 90 Electrical installation IP55 IP21...
Page 91 Electrical installation 91...
Page 92 92 Electrical installation L1, L2, L3, T1/U, R-, R+/UDC+, T2/V, T3/W UDC- (N·m) (N·m) (N·m)
Page 93: Connection Procedure For Frames R6 And R9
Electrical installation 93 Connection procedure for frames R6 and R9 1. Remove the front cover: For IP21 drives: Release the retaining clip with a screwdriver (a) and lift the cover from the bottom outwards (b). 2. For IP21 drives: Remove the cable entry box cover by undoing the mounting screws.
Page 94 94 Electrical installation IP55 IP21...
Page 95 Electrical installation 95 R8, R9...
Page 96 96 Electrical installation R8, R9...
Page 97 Electrical installation 97 Frame L1, L2, L3, T1/U, T2/V, T3/W R-, R+/UDC+, UDC- T (Wire screw) T (Terminal T (Wire screw) T (Terminal nut) nut) M… N·m M... N·m M… N·m M… N·m N·m 40 (30*) * for 525…690 V drives...
Page 98 98 Electrical installation R8, R9...
Page 99: Grounding The Motor Cable Shield At The Motor End
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 motoring mode. Contact your local ABB representative for further instructions.
Page 100: Default I/O Connection Diagram
100 Electrical installation Default I/O connection diagram XPOW External power input Wire sizes: +24VI 24 V DC, 2 A 0.5 … 2.5 mm (24…12 AWG) Reference voltage and analog inputs Tightening +VREF 10 V DC, R 1…10 kohm -VREF -10 V DC, R 1…10 kohm torques: 0.5 N·m AGND...
Page 101: Notes
Electrical installation 101 Notes: Current [0(4)…20 mA, R > 100 ohm] or voltage [ 0(2)…10 V, R > 200 kohm] input selected with jumper J1. Change of setting requires reboot of control unit. Current [0(4)…20 mA, R > 100 ohm] or voltage [ 0(2)…10 V, R >...
Page 102: External Power Supply For The Control Unit (Xpow)
102 Electrical installation External power supply for the control unit (XPOW) External +24 V (2 A) power supply for the control unit can be connected to terminal block XPOW. Using an external supply is recommended if • the control board needs to be kept operational during input power breaks, for example, due to continuous fieldbus communication •...
Page 103: Drive-To-Drive Link (Xd2D)
Electrical installation 103 Drive-to-drive link (XD2D) The drive-to-drive link is a daisy-chained RS-485 transmission line that allows basic master/follower communication with one master drive and multiple followers. Set termination activation jumper J3 (see section Jumpers and switches above) next to this terminal block to the ON position on the drives at the ends of the drive-to-drive link.
Page 104: Di6 (Xdi:6) As Ptc Sensor Input
104 Electrical installation DI6 (XDI:6) as PTC sensor input PTC sensors can be connected to this input for motor temperature measurement as follows. The sum of the sensor resistances must not exceed the threshold resistance of the digital input at the motor normal operating temperature. Do not connect both ends of the cable shield directly to ground.
Page 105: Control Cable Connection Procedure
Electrical installation 105 Control cable connection procedure WARNING! Follow the safety instructions, page 14. Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Disconnect the drive from the power line. Lock the main disconnecting device and ensure by measuring that there is no voltage.
Page 106 106 Electrical installation 0.5 N·m 1.5 N·m 1.5 N·m...
Page 107: Connecting A Pc
Electrical installation 107 Connecting a PC Connect a PC to the drive with an USB data cable (USB Type A <-> USB Type Mini- B) as follows: 1. Lift the USB connector cover from bottom upwards. 2. Insert the USB cable Mini-B plug in the control panel USB connector. 3.
Page 108: Chaining A Control Panel To Several Drives
108 Electrical installation Chaining a control panel to several drives A control panel can be chained to control several drives with standard Ethernet cables as follows: 1. Set the parameters of group 49 Panel port communication in ACS880 primary control program for each drive. 2.
Page 109: Ip55 (Ul Type 12) Drives
Electrical installation 109 IP55 (UL Type 12) drives To preserve the degree of protection: • Remove the drive front cover. • Put the cables through the control cable lead-throughs. • Connect the cables as described above. • Install the front cover. Installing optional modules Note: In frames R1 and R2, 90°...
Page 110: Modules
110 Electrical installation Wiring I/O extension, fieldbus adapter and pulse encoder interface modules See the appropriate optional module manual for specific installation and wiring instructions. See page for the routing of the cables.
Page 111: Installation Of Safety Functions Modules
Electrical installation 111 Installation of safety functions modules The safety functions module can be inserted into Slot 2 on the control unit or, in frames R7 to R9, also next to the control unit. Installation procedure into Slot 2 WARNING! Follow the safety instructions, page 14. Ignoring the instructions can cause physical injury or death, or damage to the equipment.
Page 112 112 Electrical installation...
Page 113: Installation Next To The Control Unit In Frames R7 To R9
Electrical installation 113 Installation next to the control unit in frames R7 to R9 WARNING! Follow the safety instructions, page 14. Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Disconnect the drive from the power line. Lock the main disconnecting device and ensure by measuring that there is no voltage.
Page 114 114 Electrical installation...
Page 115: Installation Checklist
If the drive will be connected to an IT (ungrounded) supply network: Optional EMC filters of type +E200 and +E202 have been disconnected. Consult ABB for the instructions. If the drive has been stored over one year: The electrolytic DC capacitors in the DC link of the drive have been reformed.
Page 116 116 Installation checklist Check that … There is an adequately sized protective earth (ground) conductor between the motor and the drive. All protective earth (ground) conductors have been connected to the appropriate terminals and the terminals have been tightened (pull conductors to check). The supply voltage matches the nominal input voltage of the drive.
Page 117: Start-Up
Start-up 117 Start-up What this chapter contains This chapter describes the start-up procedure of the drive. Startup procedure 1. Run setup of the drive control program according to the start-up instructions given in Quick start-up guide for ACS880 primary control program or in the firmware manual.
Page 118 118 Start-up...
Page 119: Fault Tracing
Fault tracing 119 Fault tracing What this chapter contains This chapter describes the fault tracing possibilities of the drive. LEDs Where Color When the LED is lit Control panel POWER Green Control unit is powered and +15 V is supplied to mounting the control panel.
Page 120 120 Fault tracing...
Page 121: Maintenance
ABB recommends annual drive inspections to ensure the highest reliability and optimum performance. For more information on maintenance counters, see the firmware manual. Consult your local ABB Service representative for more details on the maintenance. On the Internet, go to www.abb.com/searchchannels.
Page 122: Preventive Maintenance Table
122 Maintenance Preventive maintenance table...
Page 123: Heatsink
See the firmware manual for the actual signal which indicates the running time of the cooling fan. Reset the running time signal after a fan replacement. Replacement fans are available from ABB. Do not use other than ABB specified spare parts.
Page 124: Replacing The Main Cooling Fan Of Frames R1 To R3
124 Maintenance Replacing the main cooling fan of frames R1 to R3 WARNING! Follow the safety instructions, page 14. Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Disconnect the drive from the power line. Lock the main disconnecting device and ensure by measuring that there is no voltage.
Page 125: Replacing The Auxiliary Cooling Fan Of Ip55 Frames R1 To R3
Maintenance 125 Replacing the auxiliary cooling fan of IP55 frames R1 to R3 WARNING! Follow the safety instructions, page 14. Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Disconnect the drive from the power line. Lock the main disconnecting device and ensure by measuring that there is no voltage.
Page 126: Replacing The Main Cooling Fan Of Frames R4 And R5
126 Maintenance Replacing the main cooling fan of frames R4 and R5 WARNING! Follow the safety instructions, page 14. Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Disconnect the drive from the power line. Lock the main disconnecting device and ensure by measuring that there is no voltage.
Page 127: Replacing The Auxiliary Cooling Fan Of Frame R4 And Ip55 Frame R5 And Ip21 Frame R5 Types Acs880-01-Xxxx-07
Maintenance 127 Replacing the auxiliary cooling fan of frame R4 and IP55 frame R5 and IP21 frame R5 types ACS880-01-xxxx-07 WARNING! Follow the safety instructions, page 14. Ignoring the instructions can cause physical injury or death, or damage to the equipment.
Page 128: Replacing The Main Cooling Fan Of Frames R6 To R8
128 Maintenance Replacing the main cooling fan of frames R6 to R8 WARNING! Follow the safety instructions, page 14. Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Disconnect the drive from the power line. Lock the main disconnecting device and ensure by measuring that there is no voltage.
Page 129: Replacing The Auxiliary Cooling Fan Of Frames R6 To R9
Maintenance 129 Replacing the auxiliary cooling fan of frames R6 to R9 WARNING! Follow the safety instructions, page 14. Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Disconnect the drive from the power line. Lock the main disconnecting device and ensure by measuring that there is no voltage.
Page 130: Replacing The Ip55 Auxiliary Cooling Fan Of Frames R8 And R9
130 Maintenance Replacing the IP55 auxiliary cooling fan of frames R8 and R9 WARNING! Follow the safety instructions, page 14. Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Disconnect the drive from the power line. Lock the main disconnecting device and ensure by measuring that there is no voltage.
Page 131 Maintenance 131...
Page 132: Replacing The Cooling Fans Of Frame R9
132 Maintenance Replacing the cooling fans of frame R9 WARNING! Follow the safety instructions, page 14. Ignoring the instructions can cause physical injury or death, or damage to the equipment. 1. Disconnect the drive from the power line. Lock the main disconnecting device and ensure by measuring that there is no voltage.
Page 133: Replacing The Drive (Frames R1 To R5)
Maintenance 133 Replacing the drive (frames R1 to R5) This section gives instructions for replacing the drive module without the cable entry box. You can replace the drive with or without its cable entry box. The latter option allows you to leave the cables installed (except from disconnecting the conductors). WARNING! Follow the safety instructions, page 14.
Page 134: Capacitors
134 Maintenance The principle of undoing the mounting screws in frames R4 and R5 is shown below (view of an IP21 unit). Capacitors The drive intermediate DC circuit employs several electrolytic capacitors. Their lifespan depends on the operating time of the drive, loading and ambient temperature.
Page 135: Reforming The Capacitors
Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. Contact ABB if capacitor failure is suspected. Replacements are available from ABB. Do not use other than ABB specified spare parts.
Page 136: Replacing The Control Panel Battery
136 Maintenance Replacing the control panel battery The battery is housed on the rear of the control panel. Replace with a new CR 2032 battery. Dispose the old battery according to local disposal rules or applicable laws. Replacing safety functions modules (FSO-11, option +Q973) Do not repair safety functions modules.
Page 137: Technical Data
Technical data 137 Technical data What this chapter contains 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. Ratings The nominal ratings for the drives with 50 Hz and 60 Hz supply are given below. The symbols are described below the table.
Page 138 138 Technical data IEC RATINGS Drive type Frame Input Max. Output ratings size rating current ACS880- Nominal use Light-overload Heavy-duty use 115A-2 22.0 145A-2 30.0 170A-2 206A-2 274A-2 = 380…415 V 02A4-3 0.75 0.75 0.55 03A3-3 0.75 04A0-3 05A6-3 07A2-3 09A4-3 12.2 12A6-3...
Page 139 Technical data 139 IEC RATINGS Drive type Frame Input Max. Output ratings size rating current ACS880- Nominal use Light-overload Heavy-duty use = 380…500 V 02A1-5 0.75 0.75 0.55 03A0-5 0.75 03A4-5 04A8-5 05A2-5 07A6-5 12.2 11A0-5 11.0 16.0 11.0 10.4 014A-5 021A-5 11.0...
Page 140 140 Technical data IEC RATINGS Drive type Frame Input Max. Output ratings size rating current ACS880- Nominal use Light-overload Heavy-duty use = 660…690 V 07A3-7 12.2 09A8-7 14A2-7 14.2 14.2 13.5 018A-7 14.2 022A-7 18.5 18.5 026A-7 18.5 035A-7 042A-7 049A-7 061A-7 084A-7...
Page 141 Technical data 141 NEMA RATINGS Drive type Frame Input Max. Output ratings size rating current ACS880- Light-overload use Heavy-duty use = 208…240 V 04A6-2 0.75 0.55 0.75 06A6-2 0.75 07A5-2 11.2 10A6-2 10.6 12.8 10.1 16A8-2 16.8 18.0 16.0 10.6 24A3-2 24.3 28.6...
Page 142 142 Technical data NEMA RATINGS Drive type Frame Input Max. Output ratings size rating current ACS880- Light-overload use Heavy-duty use = 440…480 V 02A1-5 0.75 0.55 0.75 03A0-5 0.75 03A4-5 04A8-5 05A2-5 07A6-5 12.2 11A0-5 16.0 014A-5 021A-5 027A-5 034A-5 18.5 20.0 040A-5...
Page 143: Definitions
Note 2: To achieve the rated motor power given in the table, the rated current of the drive must be higher than or equal to the rated motor current. The DriveSize dimensioning tool available from ABB is recommended for selecting the drive, motor and gear combination.
Page 144: Ip55 (Ul Type 12) Drive Types -274A-2, 293A-3 And 260A-5
144 Technical data IP55 (UL Type 12) drive types -274A-2, 293A-3 and 260A-5 In the temperature range +40…45 °C (+104…113 °F), the rated output current is derated by 1% for every added 1 °C (1.8 °F). In the temperature range +45…55 °C (+113…131 °F), the rated output current is derated by 2.5% for every added 1 °C (1.8 °F).
Page 145: Altitude Derating
Low noise control mode derating When low noise drive control mode is used, the motor and braking powers are derated. Please, contact ABB for more information. Fuses (IEC) gG and aR fuses for protection against short-circuit in the input power cable or drive are listed below.
Page 146 146 Technical data Ultrarapid (aR) fuses (one fuse per phase) Drive Min. Input Fuse type short- current Manufacturer Type Type ACS880- circuit IEC 60263 current 087A-2 3700 Bussmann 170M3813 115A-2 7500 Bussmann 170M3814 145A-2 15000 Bussmann 170M3815 170A-2 1000 28500 Bussmann 170M3816 206A-2...
Page 147 Technical data 147 Ultrarapid (aR) fuses (one fuse per phase) Drive Min. Input Fuse type short- current Manufacturer Type Type ACS880- circuit IEC 60263 current 11A0-5 11.0 Bussmann 170M1561 014A-5 Bussmann 170M1563 021A-5 Bussmann 170M1563 027A-5 1450 Bussmann 170M1565 034A-5 1450 Bussmann 170M1565...
Page 148: Gg Fuses (Frames R1 To R6)
148 Technical data gG fuses (frames R1 to R6) Check on the fuse time-current curve to ensure the operating time of the fuse is below 0.5 seconds. Follow the local regulations. gG fuses (one fuse per phase) Drive Min. Input Fuse type short-...
Page 149 Technical data 149 gG fuses (one fuse per phase) Drive Min. Input Fuse type short- current ACS880- circuit 01… current Manufacturer Type size = 500 V 02A1-5 OFAF000H4 03A0-5 OFAF000H6 03A4-5 OFAF000H6 04A8-5 OFAF000H10 05A2-5 OFAF000H10 07A6-5 OFAF000H16 11A0-5 11.0 OFAF000H16 014A-5 2500...
Page 150: Quick Guide For Selecting Between Gg And Ar Fuses
150 Technical data Quick guide for selecting between gG and aR fuses The combinations (cable size, cable length, transformer size and fuse type) in this table fulfil the minimum requirements for the proper operation of the fuse. Use this table to select between gG and aR fuses or calculate the short-circuit current of the installation as described under Calculating the short-circuit current of the installation on page 152).
Page 151 Technical data 151 Drive type Cable type Supply transformer minimum apparent power S ACS880- (kVA) 01… Copper Aluminium Maximum cable legth Maximum cable legth with gG fuses with aR fuses 10 m 50 m 100 m 10 m 100 m 200 m 145A-3 3×95...
Page 152: Calculating The Short-Circuit Current Of The Installation
= transformer rated voltage (V) = nominal apparent power of the transformer (kVA) = cable reactance (ohm). Calculation example Drive: • ACS880-01-145A-3 • supply voltage = 410 V Transformer: • rated power S = 600 kVA • rated voltage (drive supply voltage) U = 430 V •...
Page 153: Fuses (Ul)
+ (22.19 mohm + 13.94 mohm) The calculated short-circuit current 2.7 kA is higher than the minimum short-circuit current of the drive gG fuse type OFAF00H160 (1700 A). -> The 500 V gG fuse (ABB Control OFAF00H160) can be used.
Page 154 154 Technical data Drive type Input Fuse (one fuse per phase) current ACS880-01… Manufacturer Type UL class = 208…240 V 04A6-2 Bussmann JJS-15 06A6-2 Bussmann JJS-15 07A5-2 Bussmann JJS-15 10A6-2 10.6 Bussmann JJS-20 16A8-2 16.8 Bussmann JJS-25 24A3-2 24.3 Bussmann...
Page 155 Technical data 155 Drive type Input Fuse (one fuse per phase) current ACS880-01… Manufacturer Type UL class 302A-5 Bussmann JJS-400 361A-5 Bussmann JJS-500 414A-5 Bussmann JJS-600...
Page 156: Dimensions. Weights And Free Space Requirements
156 Technical data Dimensions. weights and free space requirements Frame IP21 UL type 1 Weight Weight 15.94 14.57 6.10 8.89 15.94 14.57 6.10 9.80 18.54 16.54 6.77 10.28 18.5 22.70 19.30 7.99 10.80 28.74 23.46 7.99 10.79 28.60 22.40 9.92 14.09 34.70 23.60...
Page 157: Losses, Cooling Data And Noise
Technical data 157 Losses, cooling data and noise Drive type Frame Air flow Heat Noise ACS880-01- dissipation /min dB(A) = 208…240 V 04A6-2 06A6-2 07A5-2 10A6-2 16A8-2 24A3-2 031A-2 046A-2 061A-2 075A-2 087A-2 115A-2 145A-2 170A-2 1260 206A-2 1500 274A-2 2100 = 380…415 V...
Page 158 158 Technical data Drive type Frame Air flow Heat Noise ACS880-01- dissipation /min dB(A) 293A-3 3900 363A-3 1150 4800 430A-3 1150 6000 = 440…500 V 02A1-5 03A0-5 03A4-5 04A8-5 05A2-5 07A6-5 11A0-5 014A-5 021A-5 027A-5 034A-5 040A-5 052A-5 065A-5 1117...
Page 159 Technical data 159 Drive type Frame Air flow Heat Noise ACS880-01- dissipation /min dB(A) 084A-7 1440 098A-7 1940 119A-7 2310 142A-7 3300 174A-7 3900 210A-7 1150 4200 271A-7 1150 4800...
Page 160: Terminal And Lead-Through Data For The Power Cables
160 Technical data Terminal and lead-through data for the power cables Input, motor, resistor and DC cable terminal screw sizes, accepted wire sizes (per phase) and tightening torques (T) are given below. l denotes stripping length inside the terminal. Frame Cable lead- L1, L2, L3, T1/U, T2/V, T3/W Grounding...
Page 161 Technical data 161 ** 525…690 V drives Input, motor, resistor and DC cable terminal screw sizes, accepted wire sizes (per phase) and tightening torques (T) in US units are given below. l denotes stripping length inside the terminal. Frame Cable lead- L1, L2, L3, T1/U, T2/V, T3/W Grounding throughs...
Page 162: Ul Listed Cable Lugs And Tools
162 Technical data ** 525…690 V drives UL listed cable lugs and tools Wire size Compression lug Crimping tool kcmil/AWG Manufacturer Type Manufacturer Type No. of crimps Thomas & E10731 Thomas & TBM4S Betts 54136 Betts TBM45S Burndy YAV6C-L2 Burndy MY29-3 Ilsco CCL-6-38...
Page 163: Electrical Power Network Specification
07A3-7, ACS880-01-09A8-7, ACS880-01-14A2-7 and ACS880-01-018A-7: 150 m (492 ft) For ACS880-01-xxxx-2, ACS880-01-xxxx-3 and ACS880- 01-xxxx-5 frames R4 to R9 and for types from ACS880-01- 022A-7 to ACS880-01-271A-7: 300 m (984 ft). Note: With motor cables longer than 150 m (492 ft) the...
Page 164: Control Unit (Zcu-12) Connection Data
164 Technical data Control unit (ZCU-12) connection data Power supply 24 V (±10%) DC, 2 A (XPOW) Supplied from the power unit of the drive, or from an external power supply through connector XPOW (pitch 5 mm, wire size 2.5 mm Relay outputs RO1…RO3 Connector pitch 5 mm, wire size 2.5 mm (XRO1 …...
Page 165 Technical data 165 Reference voltage for analog Connector pitch 5 mm, wire size 2.5 mm inputs +VREF and -VREF 10 V ±1% and –10 V ±1%, R 1…10 kohm load (XAI:1 and XAI:2) Analog inputs AI1 and AI2 Connector pitch 5 mm, wire size 2.5 mm (XAI:4 …...
Page 166 166 Technical data 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 Switch J6 settings: XDIO All digital inputs and DIO1 outputs share a DIO2...
Page 167: Efficiency
Technical data 167 Efficiency Approximately 98% at nominal power level Protection classes Degree of protection IP21, IP55 (IEC/EN 60529) Enclosure types (UL508C) UL Type 1, UL Type 12. For indoor use only. Overvoltage category (IEC 60664-1) Protective class (IEC/EN 61800- 5-1) Ambient conditions Environmental limits for the drive are given below.
Page 168: Materials
IEC 62635 guidelines. To aid recycling, plastic parts are marked with an approppriate 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 169: Ce Marking
Technical data 169 Applicable standards The drive complies with the following standards. The compliance with the European Low Voltage Directive is verified according to standard EN 61800-5-1. EN 60204-1:2006 + A1 2009 Safety of machinery. Electrical equipment of machines. Part 1: General requirements. Provisions for compliance: The final assembler of the machine is responsible for installing - emergency-stop device...
Page 170: Compliance With The European Rohs Directive
170 Technical data Compliance with the European RoHS Directive The RoHS Directive defines the restriction of the use of certain hazardous substances in electrical and electronic equipment. Compliance with the European Machinery Directive The drive is an electronic product which is covered by the European Low Voltage Directive.
Page 171: Declaration Of Conformity
Technical data 171 Declaration of Conformity...
Page 172 172 Technical data...
Page 173: Compliance With The En 61800-3:2004
Technical data 173 Compliance with the EN 61800-3:2004 Definitions EMC stands for Electromagnetic Compatibility. It is the ability of electrical/electronic equipment to operate without problems within an electromagnetic environment. Likewise, the equipment must not disturb or interfere with any other product or system within its locality.
Page 174: Category C3
Equipment 2. An EMC plan for preventing disturbances is drawn up for the installation. A template is available from the local ABB representative. 3. The motor and control cables are selected as specified in the hardware manual. 4. The drive is installed according to the instructions given in the hardware manual.
Page 175: Ul Marking
USA. Suitable IEC (class aR) fuses are listed on page and UL (class T) fuses on page 153. For suitable circuit breakers, contact your local ABB representative. • For installation in the United States, branch circuit protection must be provided in accordance with the National Electrical Code (NEC) and any applicable local codes.
Page 176: Csa Marking
176 Technical data CSA marking The drives of frame sizes R1 to R3 are CSA marked. The CSA marking is pending for the other frames. The approval is valid with rated voltages. “C-tick” marking “C-tick” marking is required in Australia and New Zealand. A “C-tick” mark is attached to the 380…500 V drives to verify compliance with the relevant standard (IEC 61800- 3:2004), mandated by the Trans-Tasman Electromagnetic Compatibility Scheme.
Page 177: Dimension Drawings
Dimension drawings 177 Dimension drawings What this chapter contains This chapter contains dimension drawings of the drive.
Page 178: Frame R1 (Ip21, Ul Type 1)
178 Dimension drawings Frame R1 (IP21, UL Type 1)
Page 179: Frame R2 (Ip21, Ul Type 1)
Dimension drawings 179 Frame R2 (IP21, UL Type 1)
Page 180: Frame R3 (Ip21, Ul Type 1)
180 Dimension drawings Frame R3 (IP21, UL Type 1)
Page 181: Frame R4 (Ip21, Ul Type 1)
Dimension drawings 181 Frame R4 (IP21, UL Type 1)
Page 182: Frame R5 (Ip21, Ul Type 1)
182 Dimension drawings Frame R5 (IP21, UL Type 1)
Page 183: Frame R6 (Ip21, Ul Type 1)
Dimension drawings 183 Frame R6 (IP21, UL Type 1)
Page 184: Frame R7 (Ip21, Ul Type 1)
184 Dimension drawings Frame R7 (IP21, UL Type 1)
Page 185: Frame R8 (Ip21, Ul Type 1)
Dimension drawings 185 Frame R8 (IP21, UL Type 1)
Page 186: Frame R9 (Ip21, Ul Type 1)
186 Dimension drawings Frame R9 (IP21, UL Type 1)
Page 187: Frame R1 (Ip55, Ul Type 12)
Dimension drawings 187 Frame R1 (IP55, UL Type 12)
Page 188: Frame R2 (Ip55, Ul Type 12)
188 Dimension drawings Frame R2 (IP55, UL Type 12)
Page 189: Frame R3 (Ip55, Ul Type 12)
Dimension drawings 189 Frame R3 (IP55, UL Type 12)
Page 190: Frame R4 (Ip55, Ul Type 12)
190 Dimension drawings Frame R4 (IP55, UL Type 12)
Page 191: Frame R5 (Ip55, Ul Type 12)
Dimension drawings 191 Frame R5 (IP55, UL Type 12)
Page 192: Frame R6 (Ip55, Ul Type 12)
192 Dimension drawings Frame R6 (IP55, UL Type 12)
Page 193: Frame R7 (Ip55, Ul Type 12)
Dimension drawings 193 Frame R7 (IP55, UL Type 12)
Page 194: Frame R8 (Ip55, Ul Type 12)
194 Dimension drawings Frame R8 (IP55, UL Type 12)
Page 195: Frame R9 (Ip55, Ul Type 12)
Dimension drawings 195 Frame R9 (IP55, UL Type 12)
Page 196 196 Dimension drawings...
Page 197: Safe Torque Off Function
Safe Torque off function 197 Safe Torque off function What this chapter contains This chapter describes the Safe torque off function of the drive and gives instructions for its use. Description The Safe torque off function can be used, for example, to construct safety or supervision circuits that stop the drive in case of danger (such as an emergency stop circuit).
Page 198: Compliance With The European Machinery Directive
198 Safe Torque off function The Safe torque off function of the drive complies with • EN 61800-5-2:2007 • IEC 61508-1, -2:2010 • EN 62061:2005 /AC:2010 • EN ISO 13849-1:2008 /AC:2009 • EN ISO 13849-2:2008 • EN 60204-1:2006 + AC:2010 •...
Page 199 Safe Torque off function 199 Maximum cable lengths: • 30 m (100 ft) between activation switch (K) and drive control unit • 60 m (200 ft) between multiple drives • 60 m (200 ft) between external power supply and first drive. Note that the voltage at the INx terminals of each drive must be at least 17 V DC to be interpreted as “1”.
Page 200: Single Drive (Internal Power Supply)
200 Safe Torque off function Single drive (internal power supply) ACS880-01 OUT1 +24 V SGND Control logic UDC+ T1/U, T2/V, T3/W UDC-...
Page 201: Multiple Drives (Internal Power Supply)
Safe Torque off function 201 Multiple drives (internal power supply) ACS880-01 OUT1 +24 V SGND ACS880-01 OUT1 SGND ACS880-01 OUT1 SGND...
Page 202: Multiple Drives (External Power Supply)
202 Safe Torque off function Multiple drives (external power supply) ACS880-01 +24 V DC OUT1 +24 V SGND ACS880-01 OUT1 SGND ACS880-01 OUT1 SGND...
Page 203: Operation Principle
Safe Torque off function 203 Operation principle 1. The Safe torque off activates (the activation switch is opened, or safety relay contacts open). 2. STO inputs on the drive control unit de-energize. 3. The control unit cuts off the control voltage from the drive IGBTs. 4.
Page 204: Acceptance Test Procedure
204 Safe Torque off function Acceptance test procedure After wiring the Safe torque off function, validate its operation as follows. Setting of the control program parameters is not needed. If an FSO-xx safety functions module is installed, refer to its documentation. Action WARNING! Follow the Safety...
Page 205: Use
Safe Torque off function 205 1. Open the activation switch, or activate the safety functionality that is wired to the STO connection. 2. STO inputs on the drive control unit de-energize, and the drive control unit cuts off the control voltage from the inverter IGBTs. 3.
Page 206: Maintenance
Any failures of the Safe torque off function must be reported to ABB. Safety data (SIL, PL) The safety data for the Safe torque off function is given below.
Page 207 Safe Torque off function 207 Frame IEC 61508 (1/h) (Years) 3.84E-09 (3.84 FIT) 97.03 1.56E-4 = 525…690 V 2.89E-09 (2.89 FIT) 94.96 7.70E-5 R6…R9 3.84E-09 (3.84 FIT) 97.03 1.56E-4 Frame EN/ISO 13849-1 IEC 62061 IEC 61511 MTTF Cat. SILCL (Years) = 208…500 V 7321 >...
Page 208 208 Safe Torque off function • STO reaction time (shortest detectable break): 1 ms • STO response time: 2 ms (typical), 5 ms (maximum) • Fault detection time: Channels in different states for longer than 200 ms • Fault reaction time: Fault detection time + 10 ms •...
Page 209: Certificate
Safe Torque off function 209 Certificate...
Page 210 210 Safe Torque off function...
Page 211: Resistor Braking
Resistor braking 211 Resistor braking What this chapter contains This chapter describes how to select, protect and wire brake choppers and resistors. The chapter also contains technical data. Operation principle and hardware description Frames R1 to R4 have a built-in brake chopper as standard. Frames R5 and up can be equipped with optional built-in brake chopper (+D150).
Page 212: Selecting And Routing The Brake Resistor Cables
212 Resistor braking Note: A custom resistor can be selected within the limits imposed by the internal brake chopper of the drive: • The resistance value of the custom resistor is at least R . The braking power capacity of the resistor can be calculated from the following equation: <...
Page 213: Minimizing Electromagnetic Interference
The maximum length of the resistor cable(s) is 10 m (33 ft). EMC compliance of the complete installation Note: ABB has not verified that the EMC requirements are fulfilled with external user- defined brake resistors and cabling. The EMC compliance of the complete installation must be considered by the customer.
Page 214: Protecting The System Against Thermal Overload
An example wiring diagram is shown below. ABB resistors are equipped with a thermal switch (1) inside the resistor assembly as standard. The switch indicates overtemperature and overload.
Page 215: Protecting The Resistor Cable Against Short-Circuits
Resistor braking 215 A thermal switch (standard in ABB resistors) is required for safety reasons. The thermal switch cable must be shielded and may not be longer than the resistor cable. Wire the switch to a digital input on the drive control unit as shown in the figure below.
Page 216 216 Resistor braking Set the following parameters (ACS880 primary control program): • Disable the overvoltage control of the drive by parameter 30.30 Overvoltage control. • Set parameter 31.01 External event 1 source to point to the digital input where the thermal switch of the brake resistor is wired. •...
Page 217: Technical Data
Resistor braking 217 Technical data Ratings Drive type Internal brake Example brake resistor(s) chopper Type brcont Rcont = 208…240 V ACS880-01-04A6-2 0.75 2×JBR-01* 0.21 ACS880-01-06A6-2 2×JBR-01* 0.21 ACS880-01-07A5-2 JBR-03 0.14 ACS880-01-10A6-2 JBR-03 0.14 ACS880-01-16A8-2 SACE15RE22 ACS880-01-24A3-2 SACE15RE22 ACS880-01-031A-2 SACE15RE13 ACS880-01-046A-2...
Page 218 218 Resistor braking Drive type Internal brake Example brake resistor(s) chopper Type brcont Rcont ACS880-01-169A-3 SAFUR125F500 3600 ACS880-01-206A-3 SAFUR125F500 3600 ACS880-01-246A-3 SAFUR200F500 5400 13.5 ACS880-01-293A-3 SAFUR200F500 5400 13.5 ACS880-01-363A-3 2×SAFUR125F500** 7200 ACS880-01-430A-3 2×SAFUR125F500** 7200 = 380…500 V ACS880-01-02A1-5 0.75 2×JBR-01* 0.21...
Page 219: Degree Of Protection Of Jbr, Sace And Safur Resistors
Resistor braking 219 Drive type Internal brake Example brake resistor(s) chopper Type brcont Rcont ACS880-01-035A-7 SACE15RE22 ACS880-01-042A-7 SACE15RE22 ACS880-01-049A-7 SACE15RE22 ACS880-01-061A-7 SACE15RE13 ACS880-01-084A-7 SACE15RE13 ACS880-01-098A-7 SAFUR90F575 1800 ACS880-01-119A-7 SAFUR90F575 1800 ACS880-01-142A-7 SAFUR80F500 2400 ACS880-01-174A-7 SAFUR80F500 2400 ACS880-01-210A-7 SAFUR125F500 3600 ACS880-01-271A-7...
Page 220 220 Resistor braking...
Page 221: Common Mode, Du/Dt And Sine Filters
Checking the compatibility of the motor and drive, page 54. A common mode filter kit is available from ABB with order number is 64315811 for the drive. The kit includes three wound cores. For installation instructions of the cores, see the instruction included in the core package.
Page 222: Du/Dt Filter Types
Description, installation and technical data of the FOCH filters See FOCH du/dt filters hardware manual (3AFE68577519 [English]). Description, installation and technical data of the NOCH filters See AOCH and NOCH du/dt filters hardware manual (3AFE58933368 [English]). Sine filters Contact your local ABB representative for more information.
Page 223: Further Information
Product and service inquiries Address any inquiries about the product to your local ABB representative, quoting the type designation and serial number of the unit in question. A listing of ABB sales, support and service contacts can be found by navigating to www.abb.com/searchchannels.
Page 224 Contact us www.abb.com/drives www.abb.com/drivespartners 3AUA0000078093 Rev G (EN) EFFECTIVE. 2013-07-01...

ABB ACS880-01 Hardware Manual

1 Safety Instructions

2 Introduction to the Manual

3 Operation Principle and Hardware Description

4 Mechanical Installation

5 Planning the Electrical Installation

6 Electrical Installation

7 Installation Checklist

8 Start-Up

9 Fault Tracing

10 Maintenance

11 Technical Data

12 Dimension Drawings

13 Safe Torque off Function

14 Resistor Braking

15 Common Mode, Du/Dt and Sine Filters

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Summary of Contents for ABB ACS880-01