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ABB ACS880-04F Hardware Manual

ABB ACS880-04F Hardware Manual

Drive modules
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Summary of Contents for ABB ACS880-04F

  • Page 1 ABB industrial drives Hardware manual ACS880-04F drive modules...

  • Page 2: List Of Related Manuals

    Drive hardware manuals and guides Code (English) Drive/Converter/Inverter safety instructions Multilingual code: 3AXD50000037978 ACS880-04F drive modules hardware manual 3AXD50000034664 ACS880-04F drive modules quick installation guide 3AXD50000044913 ACS-AP-x Assistant control panels user’s manual 3AUA0000085685 ACS880-01/04 +C132 marine type-approved drives 3AXD50000010521 supplement...
  • Page 3 Hardware manual ACS880-04F drive modules Table of contents 1. Safety instructions 5. Mechanical installation 7. Electrical installation 9. Start-up  2016 ABB Oy. All Rights Reserved. 3AXD50000034664 Rev A EFFECTIVE: 2016-12-28...

  • Page 5: Table Of Contents

    Table of contents List of related manuals ........... 2 1.
  • Page 6 Additional requirements for the braking applications ..... . 60 Additional requirements for ABB high-output and IP23 motors ....60 Additional requirements for non-ABB high-output and IP23 motors .
  • Page 7 Typical power cable sizes ..........63 Alternative power cable types .
  • Page 8 Drive ............. 78 Input cable .
  • Page 9 11. Maintenance Contents of this chapter ..........107 Maintenance intervals .
  • Page 10 Control panel type ........... . 131 Efficiency .
  • Page 11 Multiple drives (external power supply) ........158 Operation principle .
  • Page 12 Product training ............173 Providing feedback on ABB Drives manuals ....... . 173...

  • Page 13: Safety Instructions

    Safety instructions 13 Safety instructions Contents of this chapter This chapter contains the safety instructions which you must obey when you install and operate the drive and do maintenance 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 14: General Safety In Installation, Start-Up And Maintenance

    14 Safety instructions General safety in installation, start-up and maintenance These instructions are for all personnel that install the drive module and do maintenance work on it. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. •...

  • Page 15: Electrical Safety In Installation, Start-Up And Maintenance

    Safety instructions 15 • The maximum number of drive power-ups is five in ten minutes. Too frequent power- ups can damage the charging circuit of the DC capacitors. • Make sure that any safety circuits (for example, emergency stop and Safe torque off) are validated in start-up.

  • Page 16: Additional Instructions And Notes

    16 Safety instructions Additional instructions and notes  WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. • If you are not a qualified electrician, do not do installation or maintenance work. •...

  • Page 17: Grounding

    Safety instructions 17 WARNING! Obey these instructions. If you ignore them, equipment malfunction and damage to the fiber optic cables can occur. • Handle the fiber optic cables with care. • When you unplug the cables, always hold the connector, not the cable itself. •...

  • Page 18: Additional Instructions For Permanent Magnet Motor Drives

    18 Safety instructions Additional instructions for permanent magnet motor drives Safety in installation, start-up and 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 and equipment malfunction can occur.

  • Page 19: Introduction To The Manual

    Introduction to the manual 19 Introduction to the manual Contents of this chapter This chapter describes the intended audience and contents of the manual. It contains a flowchart of steps in checking the delivery, installing and commissioning the drive. The flowchart refers to chapters/sections in this manual and other manuals.

  • Page 20: Contents Of The Manual

    Ordering information gives ordering information on additional components available from ABB for the drive module installation. Technical data contains the technical specifications of the drive module, eg, the ratings, sizes and technical requirements, provisions for fulfilling the requirements for CE and other markings.

  • Page 21: Quick Installation, Commissioning And Operating Flowchart

    Introduction to the manual 21 Quick installation, commissioning and operating flowchart Task Plan the mechanical and electrical installation and acquire Guidelines for planning the mechanical the accessories needed (cables, fuses, etc.). installation (page 37) Check the ambient conditions, ratings, required cooling air Guidelines for planning the electrical installation flow, input power connection, compatibility of the motor, (page 57)

  • Page 22: Terms And Abbreviations

    22 Introduction to the manual Task Connect the external control cables to the drive control unit. Connecting the control cables to the terminals of the control unit (page 88) Check the installation. Installation checklist (page 99) Commission the drive. Start-up (page 103) Commission the brake chopper (if used).
  • Page 23 Introduction to the manual 23 Term/Abbreviation Explanation FENA-21 Optional high performance Ethernet/IP™, Modbus/TCP and PROFINET IO adapter module, 2-port FEPL-01 Optional Ethernet POWERLINK fieldbus adapter module FIO-01 Optional digital I/O extension module FIO-11 Optional analog I/O extension module FPBA-01 Optional PROFIBUS DP adapter module Frame (size) Size of the drive module.
  • Page 24 24 Introduction to the manual...

  • Page 25: Operation Principle And Hardware Description

    Operation principle and hardware description 25 Operation principle and hardware description Contents of this chapter This chapter describes the operating principle and construction of the drive module.

  • Page 26: Product Overview

    26 Operation principle and hardware description Product overview The ACS880-04F 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 27: Layout

    Operation principle and hardware description 27 Layout Standard drive module configuration  The assembled standard drive module configuration is shown below. Front view Heatsink cleaning hole cover Back view Flange Drive module Hood Upper front cover External control unit with control panel holder Lower front cover Control panel Clear plastic shrouds attached...
  • Page 28 28 Operation principle and hardware description +H370 Clear plastic shroud to be attached onto the Fiber optic cables drive module input power cabling (a). Lead- through shroud for side cabling (b). Clear plastic shrouds to be attached onto the PE (ground) terminal drive module output power cabling Clear plastic shroud to be attached on top of Main cooling fans...

  • Page 29: Drive Module Without Full-Size Output Cable Connection Terminals (Option +0H371) And Ip20 Shrouds (Option +0B051), With Common Mode Filter (+E208)

    Operation principle and hardware description 29 Drive module without full-size output cable connection terminals  (option +0H371) and IP20 shrouds (option +0B051), with common mode filter (+E208) Lifting lugs 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 busbars (R+...

  • Page 30: Control Unit

    30 Operation principle and hardware description Control unit  See section Standard drive module configuration on page 27. Control panel  ACS-AP-W bluetooth control panel DPMP-01 door mounting kit (option +J410) DPMP-02 door mounting kit for surface mounting (option +J413) In the standard drive module configuration, the control panel is located in the control panel holder of the external control unit.

  • Page 31: Overview Of Power And Control Connections

    Operation principle and hardware description 31 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 Analog and digital I/O extension modules, feedback interface modules and fieldbus communication modules can be inserted into slots 1, 2 and 3.

  • Page 32: External Control Connection Terminals

    32 Operation principle and hardware description External control connection terminals  The layout of the external control connection terminals on the drive module control are shown below. Description XPOW External power input XRO1 Analog inputs Analog outputs XRO2 XD2D Drive to drive link XRO1 Relay output RO1 XRO3...

  • Page 33: External Control Unit Connection Cables

    See sections Connecting the external control unit to the drive module (page 86) and Connecting a control panel (page 94) for the actual connections. ACS880-04F ZBIB BPOW BPOW BGDR STO1 BGDR STO2 2560 mm (8.4 ft)

  • Page 34: Type Designation Label

    34 Operation principle and hardware description 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 on page 35.

  • Page 35: Type Designation Key

    +J410. The main selections are described below. Not all selections are available for all types. For more information, refer to ACS880 Ordering Information (3AXD10000014923), available on request. Code Description Basic code, eg, ACS880-04F-880A-3 Product series ACS880 ACS880 product series Type -04F...
  • Page 36 36 Operation principle and hardware description Code Description ® K469 FECA-01 EtherCAT fieldbus adapter module K470 FEPL-02 Ethernet POWERLINK fieldbus adapter module K473 FENA-11 EtherNet/IP™, Modbus/TCP and PROFINET IO fieldbus adapter module K475 FENA-21 EtherNet/IP™, Modbus/TCP and PROFINET IO fieldbus adapter module, 2-port I/O extension and feedback interface modules L500 FIO-11 analog I/O extension module...

  • Page 37: Guidelines For Planning The Mechanical Installation

    Limitation of liability You must always plan and make the installation 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. Installation alternatives The drive module can be installed from the flange onto a cabinet wall or a mounting plate with the heatsink (degree of protection of IP55) in a cooling air channel or outdoors.

  • Page 38: Channel Installation

    38 Guidelines for planning the mechanical installation Channel installation Basic requirements for the channel wall  The channel wall where the drive module is mounted on must be non-flammable and sturdy enough to carry the weight of the drive module. Installation principle ...

  • Page 39: Planning The Layout Of The Cabinet

    Guidelines for planning the mechanical installation 39 Planning the layout of the cabinet  Plan a spacious layout to ensure easy installation and maintenance. Sufficient cooling air flow, obligatory clearances, cables and cable support structures all require space. Place the control board(s) away from: •...

  • Page 40: Layout Example, Door Open

    40 Guidelines for planning the mechanical installation Layout example, door open Max. 60 mm (2.36 in.) Cabinet back plate. The maximum allowed Drive module front part (a), drive module heatsink part depth of the back plate is 60 mm (2.36 in.) in order not to cover the air flow grate at the top off the heatsink.

  • Page 41: Selecting The Busbar Material And Preparation Of The Joints

    Always fasten the drive module from its fastening points to the cabinet. For details, see the module installation instructions. WARNING! Do not fasten 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 42: Planning The Electromagnetic Compatibility (Emc) Of The Cabinet

    42 Guidelines for planning the mechanical installation Note: When the bottom grille and clear plastic shrouds around the motor cables are installed, the degree of protection of the drive module from bottom side is IP20. The carrying structure on a cable channel Cabinet side view with a bottom plate Planning the electromagnetic compatibility (EMC) of the cabinet ...

  • Page 43: Planning The Cooling

    Guidelines for planning the mechanical installation 43 • We recommend 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. Cable Cable tie Strain relief Bare cable shield Knitted wire mesh Cabinet lead-through plate...

  • Page 44: Preventing The Recirculation Of Hot Air

    The air inlet is at the bottom of the cabinet, while the outlet is at the top, either on the upper part of the door or on the roof. ABB recommends that the air outlet is on the cabinet roof.

  • Page 45: Required Free Space

    Min. 200 mm (7.87 in) Other installation positions  Contact your local ABB representative for more information. Drive module on its back If you install the drive module on its back, make sure that the hot cooling air that flows upwards from the module does not cause danger.
  • Page 46 46 Guidelines for planning the mechanical installation...

  • Page 47: Mechanical Installation

    Mechanical installation 47 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. Examining the installation site Examine the installation site: •...

  • Page 48: Moving And Unpacking The Unit

    48 Mechanical installation Moving and unpacking the unit WARNING! Obey the safety instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. Move the transport package by pallet truck to the installation site. Unpack the package as follows (see the package drawing on page 49): •...

  • Page 49: Package Drawings

    Mechanical installation 49 Package drawings  3AXD50000040437_assy Transport package contents A1 Package with no IP20 shrouds for cabling area (option 0B051) A2 Standard drive module package Drive module with factory installed options (for example, +E208), delivery documents, multilingual residual voltage warning sticker, printed multilingual installation and start-up quick guides and manuals CD.
  • Page 50 50 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 10 Clear plastic shroud for input cabling 11 Top clear plastic shroud...

  • Page 51: Checking The Delivery

    Mechanical installation 51 Box B3 contains additionally this box with option +H370 Metallic shroud with ground bar Paper fill Input cable connection terminal L3/W1 Input cable connection terminal L2/V1 Input cable connection terminal L1/U1 Cardboard box Screws and insulators in a plastic 33AXD5000009522 Checking the delivery Check that all items listed in section...

  • Page 52: Attaching The Drive Module By The Flange

    52 Mechanical installation Attaching the drive module by the flange See in chapter Dimension drawings for the mounting point and mounting plate hole dimensions. A dimension drawing of a mounting plate for a Rittal TS 8 cabinet is also given. 1.

  • Page 53: Attaching The Drive Module By The Heatsink

    Mechanical installation 53 Attaching the drive module by the heatsink 1. Attach the support brackets to the heatsink back. 2. Attach the support brackets to the wall. Combi screw M8×20 20 N·m (14.8 lbf·ft)

  • Page 54: Attaching The Metallic Shroud (Standard And With Ground Bar [Option +H370])

    54 Mechanical installation Attaching the metallic shroud (standard and with ground bar [option +H370]) Attaching the external control unit The drive control unit can be attached on a mounting plate or onto a DIN rail. Note: Connect the fiber optic, power supply and BGDR cables from the drive module to the external control unit before you attach the control unit.

  • Page 55: Attaching The External Control Unit To A Mounting Plate Or Wall

    Mechanical installation 55 Attaching the external control unit to a mounting plate or wall  1. Attach the mounting screws in the wall. 2. Lift the unit onto the screws and tighten the screws. 3aua0000130997...

  • Page 56: Attaching The External Control Unit Vertically On A Din Rail

    56 Mechanical installation Attaching the external control unit vertically on a DIN rail  1. Attach the latch (A) to the back of the control unit with three screws. 2. Click the control unit to the rail as shown below (B). 3aua0000130997 Attaching the control unit horizontally on a DIN rail ...

  • Page 57: 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 obeyed, the drive can experience problems that the warranty does not cover.

  • Page 58: Selecting The Supply Disconnecting Device

    Examining the compatibility of the motor and drive Use an asynchronous AC induction motor, permanent magnet motor, AC induction servomotor or ABB synchronous reluctance motor (SynRM motor) with the drive. Several induction motors can be connected at a time. Select the motor size and drive type from the rating tables in chapter Technical data basis of the AC line voltage and motor load.

  • Page 59: Protecting The Motor Insulation And Bearings

    The following table shows how to select the motor insulation system and when optional ABB du/dt filters, insulated N-end (non-drive end) motor bearings and ABB common mode filters are required. Failure of the motor to fulfill the following requirements or improper installation may shorten motor life or damage the motor bearings and voids the motor warranty.

  • Page 60: Additional Requirements For Explosion-Safe (Ex) Motors

    If you use an explosion-safe (EX) motor, obey 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 61: Additional Data For Calculating The Rise Time And The Peak Line-To-Line Voltage

    Guidelines for planning the electrical installation 61 and form-wound non-ABB motors with nominal power smaller than 350 kW. For bigger motors, consult the motor manufacturer. Nominal AC supply Requirement for voltage Motor insulation system ABB du/dt filter, insulated N-end bearing and ABB common mode filter <...

  • Page 62: Selecting The Power Cables

    62 Guidelines for planning the electrical installation Selecting the power cables General rules  Select the input power and motor cables according to local regulations: • Select a cable capable of carrying the drive nominal current. See section Ratings (page 119) for the rated currents. •...

  • Page 63: Typical Power Cable Sizes

    Guidelines for planning the electrical installation 63 Typical power cable sizes  The table below gives copper and aluminum cable types with concentric copper shield for the drives with nominal current. See also Terminal and lead-through data for the power cables on page 127.

  • Page 64: Power Cable Types For Restricted Use

    64 Guidelines for planning the electrical installation Power cable types for restricted use A four-conductor system (three phase conductors and a protective conductor on a cable tray) is not allowed for motor cabling (allowed for input cabling). Not allowed power cable types Symmetrical shielded cable with individual shields for each phase conductor is not allowed on any cable size for input and motor cabling.

  • Page 65: 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 66: Control Panel Cable Length And Type

    66 Guidelines for 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 67: Separate Control Cable Ducts

    Protect the drive with fuses (a) and the input cable with fuses (b) or a circuit breaker as shown below: ACS880-04F Size the fuses or the circuit breaker at the distribution board according to local regulations for the input cable protection. Select the fuses for the drive according to the instructions...

  • Page 68: Circuit Breakers

    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 69: Protecting The Drive And The Input Power And Motor Cables Against Thermal Overload

    Guidelines for planning the electrical installation 69 Protecting the drive and the input power and motor cables against  thermal overload The drive protects itself and the input and motor cables against thermal overload when the cables are dimensioned according to the nominal current of the drive. No additional thermal protection devices are needed.

  • Page 70: Implementing The Emergency Stop Function

    70 Guidelines for planning the electrical installation Implementing the Emergency stop function For safety reasons, install the emergency stop devices at each operator control station and at other operating stations where emergency stop may be needed. You can implement the emergency stop function using the Safe torque off function of the drive module (see chapter Safe torque off function on page 153).

  • Page 71: Implementing The Power Loss Ride-Through Function

    Guidelines for planning the electrical installation 71 Implementing the Power loss ride-through function Implement the power loss ride-through function as follows: 1. 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. 2.

  • Page 72: Using A Contactor Between The Drive And The Motor

    72 Guidelines for planning the electrical installation Using a contactor between the drive and the motor Implementing the control of the output contactor depends on how you select the drive to operate. See also section Implementing a bypass connection on page 72. When you have selected to use DTC motor control mode and motor ramp stop, open the contactor as follows: 1.

  • Page 73: Example Bypass Connection

    Guidelines for planning the electrical installation 73 Example bypass connection  An example bypass connection is shown below. Drive main switch Bypass circuit breaker Drive main contactor Bypass contactor Drive output contactor Drive main contactor on/off control Motor power supply selection (drive or direct-on-line) Start when motor is connected direct-on-line Stop when motor is connected direct-on-line Switching the motor power supply from drive to direct-on-line...

  • Page 74: Switching The Motor Power Supply From Direct-On-Line To Drive

    74 Guidelines for planning the electrical installation Switching the motor power supply from direct-on-line to drive 1. Stop the motor with S42. 2. Switch the motor power supply from direct-on-line to the drive with S40. 3. Close the main contactor of the drive with switch S11 (-> turn to position ST for two seconds and leave to position 1).

  • Page 75: Implementing A Motor Temperature Sensor Connection

    Guidelines for planning the electrical installation 75 Implementing a motor temperature sensor connection 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 connect a motor temperature sensor and other similar components to the drive, you have four alternatives: 1.

  • Page 76: Example Circuit Diagram

    76 Guidelines for planning the electrical installation Extension module Temperature sensor Temperature sensor type insulation requirement Type Insulation/Isolation Pt100, Pt1000 FPTC- Reinforced insulation between sensor No special requirement connector and other connectors (including drive control unit connector). Note: The inaccuracy of the drive analog inputs for Pt100 sensors is 10 °C (50 °F). If more accuracy is needed, use the FAIO-01 analog I/O extension module (option +L525).

  • Page 77: Electrical Installation

    Electrical installation 77 Electrical installation Contents of this chapter This chapter gives instructions on the wiring of the drive. Safety WARNING! If you are not a qualified electrician do not do the installation work described in this chapter. Obey the instructions in chapter Safety instructions.

  • Page 78: Checking The Insulation Of The Assembly

    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, consult the manufacturer’s instructions.

  • Page 79: Checking The Compatibility With It (Ungrounded) Systems

    Electrical installation 79 using a measuring voltage of 1 kV DC. The insulation resistance must be higher than 1 Mohm. Checking the compatibility with IT (ungrounded) systems EMC filter +E200 is not suitable for use in an IT (ungrounded) system. If the drive is equipped with filter +E200, disconnect the filter grounding wire before connecting the drive to the supply network.

  • Page 80: Grounding The Drive Module

    80 Electrical installation Grounding the drive module  Ground the drive module from its top back grounding hole to the cabinet frame or from the module PE terminal to the cabinet PE busbar. Connecting the power cables WARNING! Obey the safety instructions in chapter Safety instructions.

  • Page 81: Power Cable Connection Diagram

    Electrical installation 81 Power cable connection diagram  (PE) (PE) ACS880-04F UDC- UDC+ INPUT OUTPUT For alternatives, see section Selecting the supply disconnecting device on page In the installing example of this chapter, the disconnecting device is not in the same cubicle with the drive module.

  • Page 82: Power Cable Connection Procedure

    Aluminum-aluminum contact can cause oxidation in the contact surfaces For the standard drive module configuration: • See the step-by-step installation drawings in ACS880-04F quick installation guide (3AXD50000044913 [multilingual]) • Connect the full-size output cable connection terminals to the drive module.

  • Page 83: Dc Connection

    Electrical installation 83 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 cabinet. Ground the cable shields 360°...

  • Page 84: Removing The Control Panel Holder From The External Control Unit

    84 Electrical installation Removing the control panel holder from the external control unit 1. Disconnect the control panel cable from connector X13 on the control unit. 2. Loosen the mounting screws of the control panel holder and take the holder off.

  • Page 85: Attaching The Control Cable Clamp Plate

    Electrical installation 85 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. 0.7 N·m (6.2 lbf·in)

  • Page 86: Connecting The External Control Unit To The Drive Module

    86 Electrical installation 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. Routing the control unit cables into the drive module ...

  • Page 87: Connections To The Control Unit

    Electrical installation 87 Connections to the control unit  Connect the fiber optic, power supply and BGDR cables to the external 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. BPOW ZBIB SOIA...

  • Page 88: Connecting The Control Cables To The Terminals Of The Control Unit

    88 Electrical installation Connecting the control cables to the terminals of the control unit 1. Route the cables to the control unit as shown below. 2. Ground the shields of the control cables at the clamp plate. The shields should be continuous as close to the terminals of the control unit as possible.

  • Page 89: Default I/O Connection Diagram

    Electrical installation 89 Default I/O connection diagram  Relay outputs XRO1…XRO3 Ready 250 V AC / 30 V DC Running 250 V AC / 30 V DC Faulted(-1) 250 V AC / 30 V DC Fault External power input XPOW 24 V DC, 2 A +24VI Reference voltage and analog inputs...

  • Page 90: Notes

    90 Electrical installation Notes: 1) Current [0(4)…20 mA, R = 100 ohm] or voltage [0(2)…10 V, R > 200 kohm] input selected by jumper J1. Change of setting requires reboot of control unit. 2) Current [0(4)…20 mA, R = 100 ohm] or voltage [0(2)…10 V, R >...

  • Page 91: Ai1 And Ai2 As Pt100, Pt1000, Ptc And Kty84 Sensor Inputs (Xai, Xao)

    Electrical installation 91 AI1 and AI2 as Pt100, Pt1000, PTC and KTY84 sensor inputs (XAI, XAO) Three Pt100, Pt1000 or PTC sensors or one KTY84 sensor for motor temperature measurement can be connected between an analog input and output as shown below. Do not connect both ends of the cable shields directly to ground.

  • Page 92: Di6 (Xdi:6) As Ptc Sensor Input

    92 Electrical installation DI6 (XDI:6) as PTC sensor input One PTC sensor 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 93: Safe Torque Off (Xsto)

    Electrical installation 93 The following diagram shows the wiring of the drive-to-drive link. Safe torque off (XSTO) For the drive to start, both connections (OUT1 to IN1 and IN2) must be closed. By default, the terminal block has jumpers to close the circuit. Remove the jumpers before connecting an external Safe torque off circuitry to the drive.

  • Page 94: Connecting A Control Panel

    94 Electrical installation Connecting a control panel With door mounting kit (option +J410)), connect the control panel to the control unit as follows: 1. Connect an Ethernet cable to the RJ-45 connector of the control panel. 2. Connect the other end of the cable to the X13 connector of the control unit. Controlling several drives from one control panel through panel bus One control panel (or PC) can be used to control several drives by constructing a panel...

  • Page 95: Connecting A Pc

    Electrical installation 95 Connecting a PC You need a control panel to connect a PC to the drive module. Connect the control panel to the drive control unit as described in section Connecting a control panel on page 94. WARNING! Do not connect the PC directly to the control panel connector of the control unit as this can cause damage.
  • Page 96 96 Electrical installation 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start work. 2. If the bottom plate of the FSO 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.

  • Page 97: Installing I/O Extension, Fieldbus Adapter And Pulse Encoder Interface Modules

    Electrical installation 97 Installing I/O extension, fieldbus adapter and pulse encoder  interface modules See page for the available slots for each module. WARNING! Obey the safety instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1.

  • Page 98: Connecting The Memory Unit

    98 Electrical installation Connecting the memory unit WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start work.

  • Page 99: Installation Checklist

    Installation checklist 99 Installation checklist Contents of this chapter This chapter contains a list for checking the mechanical and electrical installation of the drive module. Installation checklist Go through the checklist below together with another person. WARNING! Obey the safety instructions in chapter Safety instructions.
  • Page 100 100 Installation checklist Check 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. Optional modules and terminals are labelled correctly. The placement of optional modules and other equipment inside the cabinet and on the cabinet door is correct.
  • Page 101 Installation checklist 101 Check that … Installation of the cabinet The drive cabinet has been attached to floor and also from top to the wall or roof. The ambient operating conditions agree with the specifications given in chapter Technical data. The cooling air will flow freely in and out of the drive cabinet, and air recirculation inside the cabinet will not be possible (air baffle plates are on place).
  • Page 102 102 Installation checklist...

  • Page 103: Start-Up

    For option +N7502, see also ACS880 drives with SynRM motors (option +N7502) supplement (3AUA0000145506 [English]). • 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 104 104 Start-up 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. See section Start-up including acceptance test on page 159. 7. For drive modules with an FSO-xx safety functions module (option +Q972 and +Q973): Test and validate the operation of the safety functions.

  • Page 105: Fault Tracing

    Fault tracing 105 Fault tracing Contents of this chapter This chapter describes the fault tracing possibilities of the drive. LEDs with options +J410 Where Color When the LED is lit Control panel POWER Green Control unit is powered and +15 V is supplied to the control mounting platform panel.
  • Page 106 106 Fault tracing...

  • Page 107: Maintenance

    If installed in an appropriate environment, the drive requires very little maintenance. 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 108: Descriptions Of Symbols

    Performance of on/off-site work (commissioning, tests, measurements or other work) Replacement of component Recommended annual maintenance actions by the user  ABB recommends these annual inspections to ensure the highest reliability and optimum performance. Action Target IP22 and IP42 air inlet and outlet meshes on the cabinet doors...

  • Page 109: Heatsink

    Maintenance 109 Heatsink The module heatsink fins pick up dust from the cooling air. The drive runs into overtemperature warnings and faults if the heatsink is not clean. Cleaning the interior of the heatsink  WARNING! Obey the safety instructions in chapter Safety instructions.

  • Page 110: Fans

    See the firmware manual for the actual signal which indicates the running time of the cooling fan. For resetting the running time signal after a fan replacement, please contact ABB. Replacement fans are available from ABB. Do not use other than ABB specified spare parts.

  • Page 111: Replacing The Circuit Board Compartment Cooling Fans

    Maintenance 111 Replacing the circuit board compartment cooling fans  WARNING! Obey the safety instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work.

  • Page 112: Replacing The Main Cooling Fans

    112 Maintenance Replacing the main cooling fans  The main cooling fans can be replaced from the front side and the back side. WARNING! Obey the safety instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. To replace the main cooling fans from the front side: 1.
  • Page 113 Maintenance 113 To replace the main cooling fans from the back side: 1. Stop the drive and do the steps in section Precautions before electrical work on page before you start the work. 2. Undo the locking screw. 3. Push the fan cassette to the left. 4.

  • Page 114: Replacing The Standard Drive Module

    It is not possible to predict a capacitor failure. The capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. Contact ABB if a capacitor failure is suspected. Replacements are available from ABB. Do not use other than ABB specified spare parts.

  • Page 115: Replacing The Control Panel Battery

    Maintenance 115 Replacing the control panel battery The battery is housed on the rear of the control panel. Replace it with a new CR 2032 battery. Dispose the old battery according to local disposal rules or applicable laws. Replacing the control unit battery Stop the drive and do the steps in section Precautions before electrical work on page...

  • Page 116: Memory Unit

    116 Maintenance Memory unit When a drive module is replaced, the parameter settings can be retained by transferring the memory unit from the defective drive module to the new module. The memory unit is located in the control unit, see page 31. WARNING! Do not remove or insert the memory unit when the drive module is powered.

  • Page 117: Ordering Information

    Notes: • This chapter only lists the installation accessories available from ABB. All other parts must be sourced from a third party by the system integrator. For a listing, refer to the kit-specific installation instructions available at https://www151.abb.com/spaces/lvacdrivesengineeringsupport/content.

  • Page 118: Fso Accessories Kit

    118 Ordering information FSO accessories kit Kit code Ordering code Illustration A-X-X-279 3AXD50000025495 Instruction code: 3AXD50000025583 Retrofit accessory kits Option Ordering code code Common mode filter kit E208 3AXD50000026145 Full size cable connection terminals for input power cables H370 3AXD50000019542 Full size cable connection terminals for output power cables 3AXD50000019544 IP20 shrouds for covering the input and motor cabling area...

  • Page 119: Technical Data

    Technical data 119 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. Ratings The ratings of the drive modules with 50 Hz and 60 Hz supply are given below. IEC RATINGS Drive type Frame...

  • Page 120: Definitions

    The power ratings apply to most IEC 34 motors at the nominal voltage of the drive. We recommend to select the drive, motor and gear combination for the required motion profile with the DriveSize dimensioning tool available from ABB. When is derating needed ...

  • Page 121: Ambient Temperature Derating

    Technical data 121 Ambient temperature derating  In the temperature range +40…55 °C (+104…131 °F), the rated output current is derated by 1% for every added 1 °C (1.8 °F) as follows. Calculate the output current by multiplying the current given in the rating table by the derating factor. Derating factor 1.00 0.85...

  • Page 122: Altitude Derating

    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 on page is used and ABB sine filter in Parameter 95.15 Special HW settings is enabled...
  • Page 123 Technical data 123 With other than recommended sine filters (see section Sine filters on page 172) and non- ABB Ex motors, contact ABB. Drive Output ratings for special settings module Ex motor (ABB Ex motor) ABB sine filter Low noise mode...

  • Page 124: High Speed Mode

    Contact ABB for operation above the recommended maximum output frequency or for the output current derating with output frequencies above 120 Hz and below the maximum output frequency.

  • Page 125: Fuses (Iec)

    Technical data 125 Fuses (IEC) aR fuses for protection against short-circuit in the input power cable or drive are listed below. Ultrarapid (aR) fuses Drive type Input Fuse ACS880-04F- current Manufacturer Type DIN 43620 Size = 400 V 504A-3 490000...

  • Page 126: Dimensions, Weights And Free Space Requirements

    126 Technical data Drive type Input Fuse ACS880-04F- current Manufacturer UL class Type 715A-5 Ferraz A4BY800 820A-5 Ferraz A4BY900 880A-5 1000 Ferraz A4BY1000 Note 1: See also Implementing thermal overload and short-circuit protection on page 67. Note 2: In multicable installations, install only one fuse per phase (not one fuse per conductor).

  • Page 127: Losses, Cooling Data And Noise

    See page 89. Electrical power network specification Voltage (U ACS880-04F-xxxx-3 drive modules: 380…415 V AC phase +10%/-15%. This is indicated in the type designation label as typical input voltage level 400 V AC. ACS880-04F-xxx-5 drive modules: 380...500 V AC 3-phase +10%/-15%. This is indicated in the type designation label as typical input voltage levels 400/480/500 V AC.

  • Page 128: Motor Connection Data

    0.98 (at nominal load) (cos phi Motor connection data Motor types Asynchronous AC induction motors, permanent magnet motors, AC induction servomotors and ABB synchronous reluctance motors (SynRM motors) Voltage (U 0 to U , 3-phase symmetrical, U at the field weakening point Frequency (f 0…500 Hz...

  • Page 129: Control Unit Connection Data (Zcu-14)

    Technical data 129 Control unit connection data (ZCU-14) Power supply 24 V (±10%) DC, 2 A (XPOW) External power supply in. With some drive module sizes, not used as the control unit is supplied from the drive module. Connector pitch 5 mm, wire size 2.5 mm Relay outputs RO1…RO3 Connector pitch 5 mm, wire size 2.5 mm (XRO1…XRO3)
  • Page 130 130 Technical data Drive-to-drive link Connector pitch 5 mm, wire size 2.5 mm (XD2D) Physical layer: RS-485 Termination by jumper Safe torque off connection Connector pitch 5 mm (0.2 in), wire size 2.5 mm2 (14 AWG) (XSTO) Input voltage range: -3…30 V DC Logic levels: “0”...

  • Page 131: Control Panel Type

    Technical data 131 Ground isolation diagram) XPOW +24VI +VREF -VREF AGND AI1+ Common mode voltage between AI1- AI2+ channels +30 V AI2- AGND AGND XD2D BGND XRO1, XRO2, XRO3 XD24 DIIL +24VD DICOM +24VD DIOGND XDIO DIO1 DIO2 XSTO OUT1 Ground * Ground selector (J6) settings (ZCU-14)

  • Page 132: Efficiency

    132 Technical data Efficiency Approximately 98% at nominal power level Protection classes Degree of protection Front: IP20 (IEC/EN 60529) Front with option +0B051: IP00 Heatsink: IP55 Enclosure type (UL 508C) Front: UL Open Type Front with option +0B051: UL Open Type Heatsink: NEMA Type 12 Overvoltage category (IEC 60664-1)

  • Page 133: Materials

    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 international and local regulations.

  • Page 134: Ce Marking

    134 Technical data EN 61800-3:2004 +A1:2012 Adjustable speed electrical power drive systems. Part 3: EMC requirements and specific test methods UL 508C (3rd edition) UL Standard for Safety, Power Conversion Equipment, third edition CSA-C22.2 No. 0-10 General Requirements - Canadian Electrical Code, Part II CSA C22.2 No.

  • Page 135: Declaration Of Conformity

    Technical data 135 Declaration of Conformity...
  • Page 136 136 Technical data...

  • Page 137: Compliance With En 61800-3:2004

    Technical data 137 Compliance with 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 138: Ul Marking

    The input cable must be protected with fuses. Circuit breakers must not be used without fuses in the USA. For suitable circuit breakers, contact your local ABB representative. Suitable IEC (class aR) fuses for drive protection are listed on page and UL fuses on page 125.

  • Page 139: Csa Marking

    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 theft of data or information.
  • Page 140 140 Technical data...

  • Page 141: Dimension Drawings

    Dimension drawings 141 Dimension drawings Contents of this chapter This chapter contains dimension drawings of the drive modules.

  • Page 142: Standard Configuration - Ip20 (Ul Open Type)

    142 Dimension drawings Standard configuration – IP20 (UL Open Type)

  • Page 143: Drive Module With Options +E208 And +H370 - Ip20 (Ul Open Type)

    Dimension drawings 143 Drive module with options +E208 and +H370 – IP20 (UL Open Type)

  • Page 144: Drive Module With Options +0B051+E208+0H371 - Ip00 (Ul Open Type)

    144 Dimension drawings Drive module with options +0B051+E208+0H371 – IP00 (UL Open Type)

  • Page 145: Drive Module With Options +0B051+E208+0H371+C217 - Ip00 (Ul Open Type)

    Dimension drawings 145 Drive module with options +0B051+E208+0H371+C217 – IP00 (UL Open Type)

  • Page 146: Drive Module With Options +0B051+0H371 - Ip00 (Ul Open Type)

    146 Dimension drawings Drive module with options +0B051+0H371 – IP00 (UL Open Type)

  • Page 147: Mounting Plate

    Dimension drawings 147 Mounting plate...
  • Page 148 148 Dimension drawings...

  • Page 149: External Control Unit

    Dimension drawings 149 External control unit 3axd50000011687...
  • Page 150 150 Dimension drawings...

  • Page 151: Example Circuit Diagram 151

    Example circuit diagram 151 Example circuit diagram Contents of this chapter This chapter shows an example circuit diagram for a cabinet-installed drive module.

  • Page 152: Example Circuit Diagram

    152 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).

  • Page 153: Safe Torque Off Function

    Safe torque off function 153 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 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 154: Compliance With The European Machinery Directive

    154 Safe torque off function Standard Name IEC 61508-1:2010 Functional safety of electrical/electronic/programmable electronic safety- related systems – Part 1: General requirements IEC 61508-2:2010 Functional safety of electrical/electronic/programmable electronic safety- related systems – Part 2: Requirements for electrical/electronic/programmable electronic safety-related systems IEC 61511:2016 Functional safety –...

  • Page 155: Grounding Of Protective Shields

    Ground the shield in the cabling between the activation switch and the control unit at the control unit. • Ground the shield in the cabling between two control units at one control unit only. Single drive (internal power supply)  Dual-channel connection ACS880-04F Control unit OUT1 +24 V SGND Control logic UDC+ T1/U2, T2/V2, T3/W2 UDC–...

  • Page 156: Single-Channel Connection

    156 Safe torque off function Single-channel connection ACS880-04F Control unit OUT1 +24 V SGND Notes: • 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 157: Multiple Drives (Internal Power Supply)

    Safe torque off function 157 Multiple drives (internal power supply)  ACS880-04F Control unit XSTO OUT1 +24 V SGND ACS880-04F Control unit XSTO OUT1 SGND ACS880-04F Control unit XSTO OUT1 SGND...

  • Page 158: Multiple Drives (External Power Supply)

    158 Safe torque off function Multiple drives (external power supply)  24 V DC ACS880-04F – Control unit XSTO OUT1 +24 V SGND ACS880-04F Control unit XSTO OUT1 SGND ACS880-04F Control unit XSTO OUT1 SGND...

  • Page 159: Operation Principle

    Safe torque off function 159 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 160 160 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. Ensure that the drive operates as follows: •...

  • Page 161: Maintenance

    If any wiring or component change is needed after start-up, or the parameters are restored, follow the test given in section Acceptance test procedure on page 159. Use only ABB approved spare parts. Record all maintenance and proof test activities in the machine logbook.

  • Page 162: Competence

    Any failures of the Safe torque off function must be reported to ABB. Safety data Note: The safety data is calculated for redundant use, and does not apply if both STO channels are not used.

  • Page 163: Abbreviations

    Safe torque off function 163 • STO fault indication (parameter 31.22) delay: < 500 ms • 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 164 164 Safe torque off function...

  • Page 165: Contents Of This Chapter

    Resistor braking 165 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. Operation principle and hardware description The dive can be equipped with optional built-in brake chopper (+D150). Brake resistors are available as add-on kits.

  • Page 166: Selecting A Custom Resistor

    166 Resistor braking which two standard resistors are connected in parallel, two in series. The E value of the four-resistor assembly is four times the value specified for the standard resistor. Selecting a custom resistor  If you use a resistor other than the default resistor, make sure that: 1.

  • Page 167: 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 168: Protecting The Resistor Cable Against Short-Circuits

    168 Resistor braking 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 169: Technical Data

    Ensure proper ventilation at the start- Technical data Ratings  Drive type Internal brake Example brake resistor(s) chopper Type brcont Rcont = 400 V ACS880-04F-504A-3 2xSAFUR125F500 2.00 7200 ACS880-04F-584A-3 2xSAFUR200F500 1.35 10800 ACS880-04F-649A-3 2xSAFUR200F500 1.35 10800...

  • Page 170: Dimensions And Weights

    25 kg (55 lb) SAFUR200F500 30 kg (66 lb) Ø 7 codes Ordering Brake resistor type ABB ordering code SAFUR125F500 68759285 SAFUR200F500 68759340 Terminals and cable lead-through data  See section Terminal and lead-through data for the power cables on page 127.

  • Page 171: Contents Of This Chapter

    58. Selection table  du/dt filter types for the drive modules are given below. Drive module du/dt filter type Drive module du/dt filter type type type ACS880-04F- ACS880-04F- = 400 V = 500 V 504A-3 FOCH0610-70 459A-5 FOCH0610-70 584A-3 FOCH0610-70...

  • Page 172: Ordering Codes

    172 du/dt and sine filters Ordering  codes Filter type ABB ordering code FOCH-0610-70 68550483 FOCH-0875-70 3AUA0000125245 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 needed? ...

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