ABB ACS880-37 Hardware Manual
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ABB ACS880-37 Hardware Manual

Industrial drives 160 to 3200 kw
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ABB INDUSTRIAL DRIVES
ACS880-37 drives (160 to 3200 kW)
Hardware manual

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Summary of Contents for ABB ACS880-37

  • Page 1 — ABB INDUSTRIAL DRIVES ACS880-37 drives (160 to 3200 kW) Hardware manual...
  • Page 3 ACS880-37 drives (160 to 3200 kW) Hardware manual Table of contents 1. Safety instructions 4. Mechanical installation 6. Electrical installation 9. Start-up 3AXD50000020437 Rev C Original instructions EFFECTIVE: 2021-01-18...

  • Page 5: Table Of Contents

    Table of contents 5 Table of contents 1 Safety instructions Contents of this chapter ................Use of warnings and notes ............... General safety in installation, start-up and maintenance ........Electrical safety in installation, start-up and maintenance ........Electrical safety precautions ..............Additional instructions and notes .............
  • Page 6 6 Table of contents Descriptions of options ................Degree of protection ................Definitions ..................IP22 (UL Type 1) ................IP42 (UL Type 1 Filtered) (option +B054) ..........IP54 (UL Type 12) (option +B055) ............Marine construction (option +C121) ............Cooling air intake through bottom of cabinet (option +C128) ......UL Listed (option +C129) ..............
  • Page 7 Availability of du/dt filter and common mode filter by drive type ..... Additional requirements for explosion-safe (EX) motors ......Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and AM_ ..................Additional requirements for braking applications ........
  • Page 8 8 Table of contents Power cable types ................Preferred power cable types .............. Alternate power cable types ............... Not allowed power cable types ............Power cable shield ................Selecting the control cables ..............Shielding ..................Signals in separate cables ..............Signals that can be run in the same cable ..........

  • Page 9: Table Of Contents

    Table of contents 9 T111 tap settings ................Connecting the control cables ..............Control cable connection procedure ............Grounding the outer shields of the control cables at the cabinet entry ..... Routing the control cables inside the cabinet ........... Connecting control cabling ..............Connecting a 230/115 V AC auxiliary voltage supply (UPS, option +G307) ..
  • Page 10 10 Table of contents DI6 as a PTC sensor input ..............AI1 or AI2 as a Pt100, Pt1000, PTC or KTY84 sensor input ......DIIL input ..................The XD2D connector ................Safe torque off (XSTO, XSTO OUT) ............FSO-xx safety functions module connection (X12) ........SDHC memory card slot ...............
  • Page 11 Table of contents 11 LCL filter ..................... Replacing the LCL filter ................ Capacitors ................... Reforming the capacitors ..............Fuses ....................Replacing the AC and DC fuses in cabinet ..........Control panel ..................Cleaning the control panel ..............Replacing the battery ................Control units ..................
  • Page 12 Frame 1×R8i+1×R8i, top cable entry/exit (+H351+H353) ......Frame 1×R8i+1×R8i with brake choppers and resistors (+D150+D151) ... Frame 1×R8i+1×R8i with sine output filter (+E206) ........Frame 2×R8i+2×R8i (eg. ACS880-37-1110A-3), IP22 ........ Frame 2×R8i+2×R8i (eg. ACS880-37-1210A-3), IP54 ........ Frame 2×R8i+2×R8i with main breaker (+F255) and common motor terminal cubicle (+H359), 1/2 ................
  • Page 13 Table of contents 13 Location and size of output terminals ............Units without common motor terminal cubicle ..........Frame 1×R8i+1×R8i (without sine output filter) ........Inverter module cubicle with two R8i modules, bottom cable exit ....Inverter module cubicle with two R8i modules, top cable exit ......Inverter module cubicle with three R8i modules, bottom cable exit ....
  • Page 14 14 Table of contents SAFUR resistor data ................Terminals and cable lead-through data of factory-installed chopper/resistor cubicles . Planning the braking system ..............Verifying the load capacity of the braking equipment ........Custom resistor ................Calculating the maximum braking power for a custom duty cycle ....Selecting and routing the cables of a custom resistor ........

  • Page 15: Safety Instructions

    Safety instructions 15 Safety instructions Contents of this chapter This chapter contains the safety instructions which you must obey when you install, start up, operate and do maintenance work on the drive. If you ignore the safety instructions, injury, death or damage can occur. Use of warnings and notes Warnings tell you about conditions which can cause injury or death, or damage to the equipment.

  • Page 16: General Safety In Installation, Start-Up And Maintenance

    16 Safety instructions General safety in installation, start-up and maintenance These instructions are for all personnel who do work on the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. •...
  • Page 17 Safety instructions 17 • Push the module into the cabinet and pull it from the cabinet carefully preferably with help from another person. Keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back. Keep your fingers away from the edges of the front flange of the module.

  • Page 18: Electrical Safety In Installation, Start-Up And Maintenance

    18 Safety instructions • Keep the cabinet doors closed when the drive is powered. With the doors open, a risk of a potentially fatal electric shock, arc flash or high-energy arc blast exists. If you cannot avoid working on a powered drive, obey the local laws and regulations on live working (including –...
  • Page 19 Safety instructions 19 WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. Go through these steps before you begin any installation or maintenance work. 1.

  • Page 20: Additional Instructions And Notes

    This can cause a health hazard. • ABB recommends against attaching the cabinet by arc welding. If you have to, obey the welding instructions in the drive manuals.

  • Page 21: Printed Circuit Boards

    Safety instructions 21 Printed circuit boards WARNING! Use a grounding wrist band when you handle printed circuit boards. Do not touch the boards unnecessarily. The boards contain components sensitive to electrostatic discharge. Grounding ￭ These instructions are for all personnel who are responsible for the grounding of the drive. WARNING! Obey these instructions.

  • Page 22: General Safety In Operation

    22 Safety instructions General safety in operation These instructions are for all personnel that operate the drive. WARNING! Obey these instructions. If you ignore them, injury or death, or damage to the equipment can occur. • Keep the cabinet doors closed when the drive is powered. With the doors open, a risk of a potentially fatal electric shock, arc flash or high-energy arc blast exists.

  • Page 23: Safety In Operation

    Safety instructions 23 Before installation, start-up and maintenance work on the drive: • Stop the drive. • Disconnect the motor from the drive with a safety switch or by other means. • If you cannot disconnect the motor, make sure that the motor cannot rotate during work. Make sure that no other system, like hydraulic crawling drives, can rotate the motor directly or through any mechanical connection like felt, nip, rope, etc.

  • Page 25: Introduction To The Manual

    Introduction to the manual 25 Introduction to the manual Contents of this chapter This chapter describes the manual. It contains a flowchart of steps in checking the delivery, installing and starting up the drive. The flowchart refers to chapters/sections in this manual and to other manuals.

  • Page 26: Use Of Component Designations

    26 Introduction to the manual Use of component designations Some device names in the manual include the item designation in brackets, for example [Q20], to make it possible to identify the components in the circuit diagrams of the drive. Quick installation, commissioning and operation flowchart Task Plan the electrical installation and acquire the accessories needed Guidelines for planning the electrical install-...

  • Page 27: Terms And Abbreviations

    Introduction to the manual 27 Terms and abbreviations Term/ Description Abbreviation ACS-AP-I Industrial assistant non-Bluetooth control panel ATEX Directives 2014/34/EU and 1999/92/EC are commonly referred to as the ATEX directives (from "Atmosphères Explosibles") BAMU Auxiliary measurement unit Type of control unit Brake chopper Conducts the surplus energy from the intermediate circuit of the drive to the brake resistor when necessary.

  • Page 28: Related Manuals

    Supply module(s) under control of one control unit, and related components. Related manuals Name Code Drive hardware manuals and guides ACS880-37 drives hardware manual 3AXD50000020437 ACX-AP-x assistant control panels user’s manual 3AUA0000085685 Drive firmware manuals and guides ACS880 primary control program firmware manual...

  • Page 29: Operation Principle And Hardware Description

    Contents of this chapter This chapter briefly describes the operation principle and construction of the drive. The ACS880-37 is a low-harmonic, air-cooled, cabinet-installed drive for controlling asynchronous AC induction motors, permanent magnet synchronous motors, AC induction servomotors and ABB synchronous reluctance (SynRM) motors.

  • Page 30: Ac Voltage And Current Waveforms

    30 Operation principle and hardware description AC fuses LCL filter Supply module (with IGBTs) DC capacitors with discharge resistors AC voltage and current waveforms ￭ The AC current is sinusoidal at a unity power factor. The LCL filter suppresses the AC voltage distortion and current harmonics.

  • Page 31: Overview Circuit Diagram Of The Drive

    Operation principle and hardware description 31 Overview circuit diagram of the drive Auxiliary voltage transformer(s) Auxiliary voltage switch [Q21]. Frame 1×R8i+1×R8i has fuse disconnectors [F20.x] in place of an auxiliary voltage switch. The auxiliary voltage is switched by the main switch/disconnector. *Main switch/disconnector [Q1.1] *AC fuses [F1.x].

  • Page 32: Cabinet Line-Up And Layout Examples

    32 Operation principle and hardware description Cabinet line-up and layout examples Frame 1×R8i+1×R8i ￭ Cabinet line-up example Auxiliary control cubicle (ACU). Contains control electronics and customer I/O connections. See section Auxiliary control cubicle (ACU) layout (page 38). Supply and inverter module cubicle. Contains the supply module, LCL filter, inverter module and switchgear, as well as the power cable terminals.
  • Page 33 Operation principle and hardware description 33 Cabinet layout example Auxiliary control cubicle (ACU). See section Auxiliary control cubicle (ACU) layout (page 38). Input cable lead-throughs, PE busbar LCL filter module Input terminals (behind LCL filter module) Main switch/disconnector [Q1.1] (behind mounting plate) AC fuses (behind mounting plate) Fuse disconnectors for auxiliary voltage [F20.x] Main contactor [Q2.1]...

  • Page 34: Frame 2×R8I+2×R8I

    34 Operation principle and hardware description Frame 2×R8i+2×R8i ￭ Cabinet line-up example Auxiliary control cubicle (ACU). Contains control electronics and customer I/O connections. See section Auxiliary control cubicle (ACU) layout (page 38). Incoming cubicle. Contains the input terminals, switchgear and charging equipment. Supply module cubicle.
  • Page 35 Operation principle and hardware description 35 Cabinet layout example Auxiliary control cubicle (ACU). See section Auxiliary control cubicle (ACU) layout (page 38). Input cable lead-throughs, PE busbar Input terminals Main switch-disconnector (Q1.1) Grounding/earthing switch [Q9.1] (option +F259) AC fuses Charging resistors and contactor Main contactor (behind charging equipment) Auxiliary voltage switch [Q21] Charging switch [Q3]...

  • Page 36: Frame 3×R8I+3×R8I (With Main Breaker, Option +F255)

    36 Operation principle and hardware description Frame 3×R8i+3×R8i (with main breaker, option +F255) ￭ Cabinet line-up example Auxiliary control cubicle (ACU). Contains control electronics and customer I/O connections. See section Auxiliary control cubicle (ACU) layout (page 38). Incoming cubicle. Contains the input terminals, switchgear and charging equipment. Supply module cubicle (1).
  • Page 37 Operation principle and hardware description 37 Cabinet layout example Auxiliary control cubicle (ACU). See section Auxiliary control cubicle (ACU) layout (page 38). Input cable lead-throughs, PE busbar Input terminals Charging resistors Incoming cubicle cooling fans (behind the charging resistor mounting plate) Main breaker [Q1] Charging switch [Q3] Auxiliary voltage switch [Q21]...

  • Page 38: Auxiliary Control Cubicle (Acu) Layout

    38 Operation principle and hardware description 40 Operation principle and hardware description Auxiliary control cubicle (ACU) layout ￭ Auxiliary control cubicle (ACU) layout A layout example of the auxiliary control cubicle (ACU) is shown below. On the left: Swing-out A layout example of the auxiliary control cubicle (ACU) is shown below. frame closed, detachable mounting plates in place.
  • Page 39 Operation principle and hardware description 39 FSO-xx safety functions module (option +Q973 Terminal blocks (X601) for motor fan connec- and other options requiring FSO-xx) tions (options +M602…610) Temperature monitoring relays (options +L505 24 V DC power supply for cabinet lighting (op- and +L506).

  • Page 40: Overview Of Power And Control Connections

    40 Operation principle and hardware description Overview of power and control connections The diagram shows the power connections and control interfaces of the drive. Drive Supply control unit [A51] Inverter control unit [A41] Slots 1, 2 and 3 Slot 4 X205 V1T/R…...

  • Page 41: Door Switches And Lights

    Operation principle and hardware description 41 Fiber optic link to each inverter module. Similarly, each supply module is connected to the supply control unit by fiber optic cables. Terminal blocks for customer connections installed in the drive cabinet. For the locations, see section Auxiliary control cubicle (ACU) layout (page 38).

  • Page 42: Main Disconnecting Device (Q1.1)

    42 Operation principle and hardware description Reserved for order-based engineered equipment EMERGENCY Emergency stop push button (with emergency stop options only) STOP The layout depends on the options selected. Main disconnecting device (Q1.1) ￭ Depending on the configuration of the drive, the main disconnecting device of the drive is either a switch-disconnector or a main circuit breaker.

  • Page 43: Control Panel

    Operation principle and hardware description 43 Control panel ￭ The ACS-AP-W is the user interface of the drive. It provides the essential controls such as Start/Stop/Direction/Reset/Reference, and the parameter settings for the inverter control program. The control panel can be removed by pulling it forward by the top edge and reinstalled in reverse order.

  • Page 44: Descriptions Of Options

    44 Operation principle and hardware description Descriptions of options Note: All options are not available for all drive types, do not coexist with certain other options, or may require additional engineering. Check actual availability with ABB. Degree of protection ￭...

  • Page 45: Cooling Air Intake Through Bottom Of Cabinet (Option +C128)

    Operation principle and hardware description 45 Additional wire markings may be required for classification. See section Wire markings (page 47). Cooling air intake through bottom of cabinet (option +C128) ￭ See section Air inlet through the bottom of cabinet (option +C128) (page 73).

  • Page 46: Emc Filter (Option +E202)

    46 Operation principle and hardware description The cubicle is equipped with blank panel entries (full panel or two-half panels) on the back. EMC filter (option +E202) ￭ EMC filter for 1st Environment (category C2) for TN (grounded) system. du/dt filter ￭...

  • Page 47: Output For Motor Space Heater (Option +G313)

    Operation principle and hardware description 47 Output for motor space heater (option +G313) ￭ The option contains: • load switch for providing electrical isolation during service • miniature circuit breaker for overcurrent protection • terminal block for heater and external heater supply connection. When the drive is powered (and not faulted), the heater is switched off.

  • Page 48: Additional Wire Markings

    48 Operation principle and hardware description • Main circuit terminals: Connector identifier (eg. "U1") marked on terminal, or on insulating material close to the terminal. Input and output main circuit cables are not marked. • Plug-in connectors of wire sets (except those that require special tools to disconnect) are labeled with connector designation (eg.

  • Page 49: Bottom Cable Entry/Exit (Options +H350 And +H352)

    Operation principle and hardware description 49 This is primarily intended for drive systems prone to high common mode currents, such as drive systems with long motor cabling connected to an ungrounded supply network. Bottom cable entry/exit (options +H350 and +H352) ￭...

  • Page 50: Additional Terminal Block X504 (Option +L504)

    50 Operation principle and hardware description Additional terminal block X504 (option +L504) ￭ The standard terminal blocks of the drive control unit are wired to the additional terminal block at the factory for customer control wiring. The terminals are spring loaded. Note: The optional modules inserted in the slots of the control unit are not wired to the additional terminal block.

  • Page 51: Thermal Protection With Pt100 Relays (Options +Nl506, +Nl514)

    Operation principle and hardware description 51 • firmware manual for parameter settings • ATEX-certified motor thermal protection functions for cabinet-built ACS880 drives (options +L513+Q971 and +L514+Q971) user's manual (3AXD50000014979 [English]) • FPTC-01 thermistor protection module (option +L536) for ACS880 drives user's manual (3AXD50000027750 [English]) •...

  • Page 52: Description

    52 Operation principle and hardware description • a contactor controlled by the drive, and • terminal block X601 for customer connections. The number of connections must be specified when ordering. The maximum number of connections available depends on the current requirement. The lower current ratings allow up to four fan connections (eg.

  • Page 53: Type Designation Label

    Quote the complete type designation and serial number when contacting technical support. .•.• , .. , jl 1111 ACS880•37•1210A·3+B055+G340+H366+K475+L504+Q951 Origin Finland Made in Finland ABB Oy Input 3N 400 VAC Hiomofie 13 1123 A 00380 Helsinki 50/60 Hz u2 aN o ... u1...

  • Page 54: Option Codes

    54 Operation principle and hardware description Code Description Voltage range 380…415 V AC. This is indicated in the type designation label as typical input voltage level (3~ 400 V 380…500 V AC. This is indicated in the type designation label as typical input voltage levels (3~ 400/480/500 V AC) 525…690 V AC.
  • Page 55 Operation principle and hardware description 55 Code Description G301 Cabinet lighting. See section Cabinet lighting (option +G301) (page 46). Terminals for connecting external control voltage (230 V AC or 115 V AC, eg. UPS). See section G307 Terminals for external control voltage (option +G307) (page 46).
  • Page 56 56 Operation principle and hardware description Code Description L504 Additional I/O terminal block. See section Additional terminal block X504 (option +L504) (page 50). Thermal protection with PTC relays (1 or 2 pcs). See section Thermal protection with PTC relays L505 (options +L505, +2L505, +L513, +2L513, +L536, +L537) (page 50).
  • Page 57 Operation principle and hardware description 57 Code Description Prevention of unexpected start-up with FSO-xx safety functions module, by activating the Safe Q950 torque off function Q951 Emergency stop (category 0) with safety relays, by opening the main breaker/contactor Q952 Emergency stop (category 1) with safety relays, by opening the main breaker/contactor Q954 Earth fault monitoring for IT (ungrounded) systems Q957...

  • Page 59: Mechanical Installation

    Mechanical installation 59 Mechanical installation Contents of this chapter This chapter describes the mechanical installation procedure of the drive. Examining the installation site Examine the installation site. Make sure that: • The installation site is sufficiently ventilated or cooled to remove heat from the drive. See the technical data.

  • Page 60: Necessary Tools

    60 Mechanical installation Do not install the drive on an elevated platform or a recess. The module extraction/installation ramp included with the drive is only suitable for a height difference of 50 mm (2 in) maximum (ie. the standard plinth height of the drive). Necessary tools The tools required for moving the unit to its final position, fastening it to the floor and wall and tightening the connections are listed below:...

  • Page 61: Moving And Unpacking The Drive

    Mechanical installation 61 Moving and unpacking the drive Move the drive in its original packaging to the installation site as shown below to avoid damaging the cabinet surfaces and door devices. When you are using a pallet truck, check its load capacity before you move the drive. The drive cabinet is to be moved in the upright position.

  • Page 62: Lifting The Crate With A Crane

    62 Mechanical installation Lifting the crate with a crane WARNING! Incorrect lifting can cause danger or damage. Obey the local laws and regulations applicable to lifting, such as requirements for planning the lift, for capacity and condition of lifting equipment, and for training of personnel. Lifting point Optimal position for the lifting sling: as close to the traverse board as possible...

  • Page 63: Moving The Crate With A Forklift

    Mechanical installation 63 Mechanical installation 61 Moving the crate with a forklift Moving the crate with a forklift 750 mm (29.5'') Removing the transport package ￭ Remove the transport package as follows: 1. Undo the screws that attach the wooden parts of the transport crate to each other. 2.

  • Page 64: Moving The Unpacked Drive Cabinet

    Removing the transport package  Remove the transport package as follows: 64 Mechanical installation 1. Undo the screws that attach the wooden parts of the transport crate together. 2. Remove the wooden parts. Moving the unpacked drive cabinet ￭ 3. Remove the clamps with which the drive cabinet is mounted onto the transport pallet by undoing the fastening screws.

  • Page 65: Moving The Cabinet On Rollers

    Mechanical installation 65 Moving the cabinet on rollers WARNING! Do not move marine versions (option +C121) on rollers. Lay the cabinet on the rollers and move it carefully until close to its final location. Remove the rollers by lifting the unit with a crane, forklift, pallet truck or jack. Moving the cabinet on its back WARNING! Do not transport the drive with an LCL or L filter on its back.

  • Page 66: Final Placement Of The Cabinet

    66 Mechanical installation Final placement of the cabinet Move the cabinet into its final position with a slate bar (spud bar). Place a piece of wood between the edge of the cabinet and the bar to protect the cabinet frame.

  • Page 67: Attaching The Cabinet To The Floor And Wall Or Roof

    Mechanical installation 67 Attaching the cabinet to the floor and wall or roof General rules ￭ • The drive must be installed in an upright vertical position. • Leave 400 mm (15.75”) of free space above the basic roof level of the cabinet for cooling. •...

  • Page 68: Attaching The Cabinet (Non-Marine Units)

    68 Mechanical installation Attaching the cabinet (non-marine units) ￭ Alternative 1 – Clamping 1. Insert the clamps (included) into the twin slots along the front and rear edges of the cabinet frame body and fasten them to the floor with a bolt. The recommended maximum distance between the clamps in the front edge is 800 mm (31.5”).

  • Page 69: Alternative 2 - Using The Holes Inside The Cabinet

    Mechanical installation 69 Alternative 2 – Using the holes inside the cabinet 1. Attach the cabinet to the floor through the bottom fastening holes with M10 to M12 (3/8” to 1/2”) bolts. The recommended maximum distance between the front edge fastening points is 800 mm (31.5”).

  • Page 70: Attaching The Cabinet (Marine Units)

    70 Mechanical installation Attaching the cabinet (marine units) ￭ See the dimension drawing delivered with the drive for details of the fastening points. Fasten the cabinet to the floor and roof (wall) as follows: 1. Bolt the unit to the floor through the flat bars at the base of the cabinet using M10 or M12 screws.

  • Page 71: Joining Cabinet Sections Together

    Mechanical installation 71 Joining cabinet sections together Wide cabinet line-ups are delivered in multiple sections. The sections are to be joined on-site using a 200 mm wide joining cubicle at the end of one section (a common motor terminal cubicle can also act as a joining cubicle). The screws required for the joining are enclosed in a plastic bag inside the cabinet.
  • Page 72 72 Mechanical installation 8. Use the joint pieces to connect the DC busbars. Tighten the bolts to 55…70 N·m (40…50 lbf·ft). Units with single DC busbars 55…70 N·m 55…70 N·m (40…50 lbf·ft) (40…50 lbf·ft) Units with double DC busbars Joint piece Plain washer with electroplated zinc coating and blue chromate passivation Spring washer with mechanically sprayed zinc coating WARNING!

  • Page 73: Miscellaneous

    Arc welding ￭ ABB does not recommend attaching the cabinet by arc welding. However, if arc welding is the only option, connect the return conductor of the welding equipment to the cabinet frame at the bottom within 0.5 meters (1’6”) of the welding point.

  • Page 74: Air Outlet Duct On The Cabinet Roof (Option +C130)

    74 Mechanical installation Air inlet area Support the plinth of the cabinet all round. The air duct must be able to supply a sufficient volume of cooling air. See technical data for the minimum air flow values. Top cable entry adapter and joining cubicles have no air inlet. WARNING! Make sure that the incoming air is sufficiently clean.

  • Page 75: Calculating The Required Static Pressure Difference

    Mechanical installation 75 backward to the drive in any case, even during off-time or while servicing the drive or the ventilation system. Calculating the required static pressure difference The required static pressure difference between the exit air duct and the drive installation room can be calculated as follows: Δp = (1.5…2) ·...

  • Page 76: Lifting Lugs And Bars

    76 Mechanical installation Lifting lugs and bars Certificate of conformity ￭ The certificate is available in ABB Library at www.abb.com/drives/documents (document number 3AXD10001061361). Declaration of Conformity ￭...
  • Page 77 Mechanical installation 77...

  • Page 79: Guidelines For Planning The Electrical Installation

    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 80: Examining The Compatibility Of The Motor And Drive

    Examining the compatibility of the motor and drive Use asynchronous AC induction motors, permanent magnet synchronous motors, AC induction servomotors or ABB synchronous reluctance motors (SynRM motors) with the drive. Select the motor size and drive type from the rating table on basis of the AC line voltage and motor load.
  • Page 81 Guidelines for planning the electrical installation 81 This table shows the requirements when an ABB motor is in use. Motor type Nominal AC line Requirement for voltage Motor insula- ABB du/dt and common mode filters, insulated tion system N-end motor bearings <...
  • Page 82 82 Guidelines for planning the electrical installation This table shows the requirements when a non-ABB motor is in use. Motor type Nominal AC line Requirement for voltage Motor insula- ABB du/dt and common mode filters, insulated tion system N-end motor bearings <...

  • Page 83: Availability Of Du/Dt Filter And Common Mode Filter By Drive Type

    If you will use an explosion-safe (EX) motor, follow the rules in the requirements table above. In addition, consult the motor manufacturer for any further requirements. Additional requirements for ABB motors of types other than M2_, M3_, M4_, HX_ and Use the selection criteria given for non-ABB motors.

  • Page 84: Additional Data For Calculating The Rise Time And The Peak Line-To-Line Voltage

    84 Guidelines for planning the electrical installation If you plan to use a non-ABB high-output motor or an IP23 motor, consider these additional requirements for protecting the motor insulation and bearings in drive systems: • If motor power is below 350 kW: Equip the drive and/or motor with the filters and/or bearings according to the table below.

  • Page 85: Additional Note For Sine Filters

    Guidelines for planning the electrical installation 85 Û du/dt ------------ - (1/ s) l (m) Motor cable length Û Relative peak line-to-line voltage (du/dt)/U Relative du/dt value Note: Û and du/dt values are approximately 20% higher during resistor braking. Additional note for sine filters A sine filter also protects the motor insulation system.

  • Page 86: Typical Power Cable Sizes

    86 Guidelines for planning the electrical installation required in 411.3.2. of IEC 60364-4-41:2005 and be capable of withstanding the prospective fault current during the disconnection time of the protective device. The cross-sectional area of the protective conductor can either be selected from the table below or calculated according to 543.1 of IEC 60364-5-54.

  • Page 87: Alternate Power Cable Types

    Guidelines for planning the electrical installation 87 Cable type Use as input power cabling Use as motor cabling Symmetrical shielded (or armored) cable with three phase conductors and symmetrically constructed PE conductor and a shield (or armor) Symmetrical shielded (or armored) cable with three phase conductors and a shield (or armor), and separ- ate PE conductor/cable...

  • Page 88: Not Allowed Power Cable Types

    88 Guidelines for planning the electrical installation Cable type Use as input power cabling Use as motor cabling WARNING! A single-core cable system: three If you use unshielded phase conductors and PE conductor single-core cables in an IT on cable tray network, make sure that the non-conductive outer sheath (jacket) of the cables...

  • Page 89: Selecting The Control Cables

    Relay cable ￭ The cable type with braided metallic shield (for example ÖLFLEX by LAPPKABEL, Germany) has been tested and approved by ABB. Control panel to drive cable ￭ Use EIA-485 with male RJ-45 connector, cable type Cat 5e or better. The maximum permitted...

  • Page 90: Pc Tool Cable

    90 Guidelines for planning the electrical installation PC tool cable ￭ Connect the Drive composer PC tool to the drive through the USB port of the control panel. Use a USB Type A (PC) - Type Mini-B (control panel) cable. The maximum length of the cable is 3 m (9.8 ft).

  • Page 91: Continuous Motor Cable Shield/Conduit Or Enclosure For Equipment On The Motor Cable

    Guidelines for planning the electrical installation 91 Continuous motor cable shield/conduit or enclosure for equipment ￭ on the motor cable To minimize the emission level when safety switches, contactors, connection boxes or similar equipment are installed on the motor cable between the drive and the motor: •...

  • Page 92: Protecting The Motor Against Thermal Overload

    92 Guidelines for planning the electrical installation WARNING! If the drive is connected to multiple motors, use a separate circuit breaker or fuses for protecting each motor cable and motor against overload. The drive overload protection is tuned for the total motor load. It may not trip due to an overload in one motor circuit only.

  • Page 93: Implementing The Emergency Stop Function

    Guidelines for planning the electrical installation 93 Implementing the emergency stop function You can order the drive with an emergency stop function (option). See the appropriate option manual for more information. Option User’s manual Manual code code (English) +Q951 Emergency stop, stop category 0 (using main contactor/breaker) 3AUA0000119895 +Q952 Emergency stop, stop category 1 (using main contactor/breaker)

  • Page 94: Implementing The Functions Provided By The Fso-Xx Safety Functions Module

    94 Guidelines for planning the electrical installation User's manual Manual code (English) ATEX-certified Safe disconnection function, Ex II (2) GD for ACS880 drives (+Q971) 3AUA0000132231 application guide FPTC-02 ATEX-certified thermistor protection module, Ex II (2) GD (option +L537+Q971) 3AXD50000027782 for ACS880 drives user's manual ATEX-certified motor thermal protection functions for cabinet-built ACS880 drives (options 3AXD50000014979 +L513+Q971 and +L514+Q971) user’s manual...

  • Page 95: Implementing A Bypass Connection

    IEC/EN 61800-5-1, subclause 6.5.3, for example, “THIS MACHINE STARTS AUTOMATICALLY”. Bypass connection is available as a factory-installed option for some cabinet-installed drive types. Consult ABB for more information. WARNING! Never connect the drive output to the electrical power network. The connection may damage the drive.

  • Page 96: Using A Safety Switch Between The Drive And The Motor

    96 Guidelines for planning the electrical installation Using a safety switch between the drive and the motor ABB recommends to install a safety switch between the permanent magnet motor and the drive output. The switch is needed to isolate the motor from the drive during maintenance work on the drive.

  • Page 97: Implementing A Motor Temperature Sensor Connection

    Guidelines for planning the electrical installation 97 230 V AC 230 V AC + 24 V DC Relay output Varistor RC filter Diode Implementing a motor temperature sensor connection WARNING! IEC 61800-5-1 requires double or reinforced insulation between live parts and accessible parts when: •...

  • Page 98: Connecting Motor Temperature Sensor To The Drive Via An Option Module

    98 Guidelines for planning the electrical installation 3. You can connect the sensor to the drive via an option module. The sensor and the module must form a double or reinforced insulation between the motor live parts and the drive control unit. See Connecting motor temperature sensor to the drive via an option module (page 98).

  • Page 99: Electrical Installation

    Electrical installation 99 Electrical installation Contents of this chapter This chapter gives instructions on the wiring of the drive. Warnings WARNING! Only qualified electricians are allowed to carry out the work described in this chapter. Follow the safety instructions on the first pages of this manual. Ignoring the safety instructions can cause injury or death.

  • Page 100: Compatibility Check - It (Ungrounded) Earthing System

    Use a measuring voltage of 1000 V DC. The insulation resistance of an ABB motor must be more than 100 Mohm (reference value at 25 C [77°F]). For the insulation resistance of other motors, refer to the manufacturer’s instructions.

  • Page 101: T21 And T101 Tap Settings (400

    Electrical installation 101 T21 and T101 tap settings (400…500 V units) ￭ T21_X1 T21_X2 T101_X1 T101_X2 500 V 230 V 480 V 460 V 440 V 415 V 400 V 380 V T21 and T101 tap settings (690 V units) ￭...

  • Page 102: T111 Tap Settings

    llation 102 Electrical installation ettings T111 tap settings ￭ 3~ input 3~ output 3~ input 3~ output Tap settings Terminals 3~ input 3~ output Supply Terminals 400 V 320/340 V Tap settings Terminals voltage A1– B1– C1– (50 Hz) (60 Hz) Terminals 400 V 320/340 V...

  • Page 103: Connecting The Control Cables

    Electrical installation 103 Connecting the control cables See chapter Control units of the drive (page 133) for the default I/O connections of the inverter unit (with the ACS880 primary control program). The default I/O connections can be different with some hardware options, see the circuit diagrams delivered with the drive for the actual wiring.
  • Page 104 104 Electrical installation • Cut the shield at the midpoint of the bare part. Be careful not to cut the conductors or the grounding wire (if present). • Turn the shield inside out to expose its conductive surface. • Cover the turned shield and the stripped cable with copper foil to keep the shielding continuous.

  • Page 105: Routing The Control Cables Inside The Cabinet

    Electrical installation Electrical installation 105 5. Arrange the bunches according to size from thickest to the thinnest between the E 5. Arrange the bunches according to size from thickest to the thinnest between the EMI conductive cushions. conductive cushions. 6. If more than one cable go through a grommet, seal the grommet by applying Loctite 5221 (or equivalent adhesive sealant) inside the grommet.

  • Page 106: Connecting A 230/115 V Ac Auxiliary Voltage Supply (Ups, Option +G307)

    106 Electrical installation Notes: • Do not ground the outer shield of the cable here since it is grounded at the cable entry. • Keep any signal wire pairs twisted as close to the terminals as possible. Twisting the wire with its return wire reduces disturbances caused by inductive coupling. At the other end of the cable, leave the shields unconnected or ground them indirectly via a high-frequency capacitor with a few nanofarads, eg.

  • Page 107: Connecting The Emergency Stop Push Buttons (Options +Q951, +Q952, +Q963, +Q964, +Q978,+Q979)

    Electrical installation 107 X307 Internal wiring of UPS supervision: circuit breaker or fuse off/fault = contact open. Connecting the emergency stop push buttons (options +Q951, +Q952, +Q963, +Q964, +Q978,+Q979) Connect external emergency stop push buttons according to the circuit diagrams delivered with the drive.

  • Page 108: Wiring The Pt100 Relays (Option +Nl506)

    102 Electrical installation Wiring the thermistor relay(s) (options +L505 and +2L505) The external wiring of option +2L505 (two thermistor relays) is shown below. For example, 108 Electrical installation one relay can be used to monitor the motor windings, the other to monitor the bearings. The maximum contact load capacity is 250 V AC 10 A.

  • Page 109: Wiring The Pt100 Relays (Option +Nl514)

    Electrical installation 109 X506 1 × Pt100 Sensor 1 Sensor 2 … … … Sensor 8 Internal wiring for overheat indication Overtemperature = contact open. Sensors 1 to 3 Sensors 4 and 5 Sensors 6 to 8 Wiring the Pt100 relays (option +nL514) External wiring of three Pt100 sensor modules is shown below.

  • Page 110: Powering The Heating And Lighting Equipment (Options +G300, +G301 And +G313)

    104 Electrical installation 110 Electrical installation Powering the heating and lighting equipment (options +G300, +G301 and +G313) Powering the heating and lighting equipment (options +G300, +G301 and +G313) See the circuit diagrams delivered with drive. See the circuit diagrams delivered with drive. Connect the external power supply wires for the cabinet heater and lighting to terminal block Connect the external power supply wires for the cabinet heater and lighting to terminal X300 at the back of the mounting plate.

  • Page 111: Connecting The Motor Cables (Units Without Common Motor Terminal Cubicle Or Sine Output Filter)

    Electrical installation 105 Wiring ground fault monitoring for IT ungrounded systems (option +Q954) Electrical installation 111 We recommend to connect Alarm 1 for drive tripping and Alarm 2 for alarm signals in order to avoid unnecessary trippings due to the ground fault monitor self testing with Alarm 2. X954 Internal wiring: Ground fault alarm 1.

  • Page 112: Motor Connection Diagram (With Option +H366)

    112 Electrical installation Inverter unit cubicle(s) Motor connection diagram (with option +H366) ￭ With option +H366, the output busbars of the inverter modules within the same cubicle are connected by bridging busbars. The bridging balances the motor current between the modules, which allows more cabling options.

  • Page 113: Procedure

    Refer to the drawings below. Note: As an alternative to using the extraction/installation ramp, a lifter is available from ABB Service. See Lifter for air-cooled drive modules user's guide (3AXD50000332588 [English]). WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur.
  • Page 114 114 Electrical installation 11. Pull the module carefully out along the ramp. While pulling on the handle with your right hand, keep a constant pressure with one foot on the base of the module to prevent the module from falling on its back. Electrical installation 109 12.
  • Page 115 Electrical installation 115 110 Electrical installation...

  • Page 116: Removing The Fan Carriage Of An Inverter Module

    Electrical installation 111 116 Electrical installation Removing the fan carriage of an inverter module Refer to the drawings below. WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1.
  • Page 117 Electrical installation 117 5. Remove the two screws at the bottom of the fan carriage. WARNING! Before you proceed, make sure the two screws holding the top of the inverter module are in place. 6. Remove the two screws at the top of the fan carriage. (During reassembly, tighten these screws to 22 N·m [16 lbf·ft].) Note: Units with marine or seismic design have an additional transverse bracket that is attached to the module with these screws.

  • Page 118: Connecting The Motor Cables

    Electrical installation 113 118 Electrical installation Connecting the motor cables Refer to the drawings below. WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. 1. Do the steps in section Electrical safety precautions (page 18) before you start the work.
  • Page 119 Electrical installation 119 3. For 360° grounding of the shield at the cable entry, remove the outer jacket of each cable where they pass through the cable entry (a). 4. Cut the cable to suitable length and strip the ends of the individual conductors. Twist the shield strands together to form a separate conductor and wrap it with tape.
  • Page 120 120 Electrical installation 360° grounding detail...

  • Page 121: Re-Installing The Fan Carriage Of An Inverter Module

    Electrical installation 121 Re-installing the fan carriage of an inverter module (If the inverter module was removed completely instead of only the fan carriage, proceed to section Re-inserting the inverter modules into the cubicle (page 121)). The re-installation of the fan carriage is the removal procedure in reverse. See section Removing the fan carriage of an inverter module (page 116).

  • Page 122: Connecting The Motor Cables (Units With Common Motor Terminal Cubicle Or Sine Output Filter)

    122 Electrical installation 9. Reconnect terminal block [X50] at the top of the module. 10. Reconnect the wiring and fiber optic cables to the terminals on the front of the module. 11. Repeat the procedure for the other inverter modules. 12.

  • Page 123: Connecting An External Brake Resistor Assembly

    Electrical installation 123 118 Electrical installation 3. Lead the cables into the cubicle. Make the 360° earthing arrangement at the cable entry 3. Lead the cables into the cubicle. Make the 360° earthing arrangement at the cable as shown. entry as shown. Grommet 4.

  • Page 124: Connecting The Input Power Cables

    124 Electrical installation Connecting the input power cables Connection diagram ￭ LCL filter IGBT supply modules Components for charging circuit ICU cubicle ISU cubicle Notes: Fuses or other protection means. Use a separate grounding (PE) cable (2a) or a cable with separate PE conductor (2b) if the conductivity of the shield does not meet the requirement for the PE conductor.
  • Page 125 Electrical installation 125 6. Prepare the ends of the cables. WARNING! Apply grease to stripped aluminum conductors before attaching them to non-coated aluminum cable lugs. Obey the grease manufacturer's instructions. Aluminum-aluminum contact can cause oxidation in the contact surfaces. 7. If fire insulation is used, make an opening in the mineral wool sheet according to the diameter of the cable.
  • Page 126 126 Electrical installation 9. Attach the conductive sleeves to the cable shields with cable ties. Tie up the unused conductive sleeves with cable ties. 10. Connect the twisted shields of the cables to the PE busbar of the cabinet. 11. Connect the phase conductors of the input cable to the L1, L2 and L3 terminals. Tighten the screws to the torque given under Tightening torques (page 209).

  • Page 127: Connecting A Pc

    Electrical installation 127 Connecting a PC WARNING! Do not connect the PC directly to the control panel connector of the control unit as this can cause damage. A PC (with eg, the Drive composer PC tool) can be connected as follows: 1.
  • Page 128 128 Electrical installation 3. Switch on the bus termination on the drive that is farthest from the control panel in the chain. • With drives that have the panel mounted on the front cover, move the terminating switch into the outer position. •...
  • Page 129 Electrical installation 129 With FDPI-02 modules:...

  • Page 130: Installing Option Modules

    130 Electrical installation Installing option modules Mechanical installation of I/O extension, fieldbus adapter and pulse ￭ encoder interface modules See hardware description for the available slots for each module. Install the option modules as follows: WARNING! Obey the instructions in chapter Safety instructions.
  • Page 131  Mechanical installation of an FSO-xx safety functions module This procedure describes the mechanical installation of an FSO-xx safety functions module onto the inverter control unit. (The FSO-xx can alternatively be installed beside the control unit, which is the standard with factory-installed FSO-xx modules. For instructions, Electrical installation 131 see the FSO-xx manual.) 1.

  • Page 132: Wiring Of Option Modules

    132 Electrical installation Wiring of option modules ￭ See the appropriate optional module manual for specific installation and wiring instructions.

  • Page 133: Control Units Of The Drive

    Control units of the drive 133 Control units of the drive Contents of this chapter This chapter • describes the connections of the control unit(s) used in the drive, • contains the specifications of the inputs and outputs of the control unit(s). General The drive utilizes BCU-x2 control units.

  • Page 134: Bcu-X2 Layout

    134 Control units of the drive BCU-x2 layout Description I/O terminals (see following diagram) SLOT 1 I/O extension, encoder interface or fieldbus adapter module connection. (This is the sole location for an FDPI-02 diagnostics and panel interface.) SLOT 2 I/O extension, encoder interface or fieldbus adapter module connection SLOT 3 I/O extension, encoder interface, fieldbus...
  • Page 135 Control units of the drive 135 Description Analog inputs Analog outputs Digital inputs, Digital input interlock (DIIL) XRO3 XD24 XPOW XDIO Digital input/outputs XD2D Drive-to-drive link XRO2 XD24 +24 V output (for digital inputs) XDIO XETH Ethernet port – Not in use XPOW External power input XRO1...

  • Page 136: Default I/O Diagram Of The Supply Control Unit

    136 Control units of the drive Default I/O diagram of the supply control unit The diagram below shows the default I/O connections on the supply control unit (A51), and describes the use of the connections in the supply unit. Under normal circumstances, the factory-made wiring should not be changed.
  • Page 137 Control units of the drive 137 Use of the signal in the control program. When parameter 120.30 External charge enable has value Yes (default setting), the control program reserves this I/O terminal for external charging circuit control and monitoring, and parameters 110.24 RO1 source and 110.30 RO3 source are write-protected.

  • Page 138: Default I/O Diagram Of The Inverter Control Unit (A41)

    138 Control units of the drive Default I/O diagram of the inverter control unit (A41) The diagram below shows the default I/O connections on the inverter control unit (A41), and describes the use of the connections in the inverter unit. Under normal circumstances, the factory-made wiring should not be changed.

  • Page 139: Additional Information On The Connections

    Control units of the drive 139 Notes: See section The XD2D connector (page 141). See chapter The Safe torque off function (page 251). 0 = Acceleration/deceleration ramps defined by parameters 23.12/23.13 in use. 1 = Acceleration/deceleration ramps defined by parameters 23.14/23.15 in use. Constant speed 1 is defined by parameter 22.26.

  • Page 140: Ai1 Or Ai2 As A Pt100, Pt1000, Ptc Or Kty84 Sensor Input

    140 Control units of the drive WARNING! As the inputs pictured above are not insulated according to IEC 60664, the connection of the motor temperature sensor requires double or reinforced insulation between motor live parts and the sensor. If the assembly does not fulfill the requirement, protect the I/O board terminals against contact and do not connected them to other equipment, or isolate the temperature sensor from the I/O terminals.

  • Page 141: The Xd2D Connector

    (nominal impedance 100 to 165 ohm, for example Belden 9842) for the wiring. For best immunity, ABB recommends high quality cable. Keep the cable as short as possible. Avoid unnecessary loops and parallel runs near power cables such as motor cables.

  • Page 142: Connector Data

    142 Control units of the drive Connector data Power supply (XPOW) Connector pitch 5 mm, wire size 2.5 mm 24 V (±10%) DC, 2 A External power input. Two supplies can be connected for redundancy. Relay outputs RO1…RO3 Connector pitch 5 mm, wire size 2.5 mm (XRO1…XRO3) 250 V AC / 30 V DC, 2 A Protected by varistors...
  • Page 143 Control units of the drive 143 Analog outputs AO1 and AO2 (XAO) Connector pitch 5 mm, wire size 2.5 mm 0…20 mA, R < 500 ohm load Frequency range: 0…500 Hz Resolution: 11 bit + sign bit Inaccuracy: 2% of full scale range XD2D connector Connector pitch 5 mm, wire size 2.5 mm Physical layer: RS-485...

  • Page 144: Bcu-X2 Ground Isolation Diagram

    144 Control units of the drive BCU-x2 ground isolation diagram ￭ XPOW +24VI +24VI +VREF -VREF AGND AI1+ AI1- AI2+ AI2- AGND AGND XD2D BGND SHIELD XRO1, XRO2, XRO3 XD24 +24VD DICOM +24VD DIOGND XDIO DIO1 DIO2 DIOGND DIOGND DIIL XSTO SGND XSTO OUT...

  • Page 145: Installation Checklist

    Installation checklist 145 Installation checklist Contents of this chapter This chapter contains a checklist of the mechanical and electrical installation of the drive. Checklist Examine the mechanical and electrical installation of the drive before start-up. Go through the checklist together with another person. WARNING! Obey the safety instructions of the drive.
  • Page 146 146 Installation checklist Make sure that … If the drive is connected to a network other than a symmetrically grounded TN-S system: You have done all the required modifications (for example, you may need to disconnect the EMC filter or ground- to-phase varistor).

  • Page 147: Start-Up

    Start-up 147 Start-up Contents of this chapter This chapter contains the start-up and switch-off procedures of the drive. Start-up procedure The tasks which are needed in certain cases only are marked with underlining, and option codes are given in brackets. Default device designations (if any) are given in brackets after the name, for example “main switch-disconnector [Q1]”.
  • Page 148 148 Start-up Action Check that the main switch-disconnector (Q1.1) is switched off, or main breaker (Q1) racked out. Check that the grounding switch (Q9.1) (option +F259) is switched on. Check the mechanical and electrical installation of the drive. See Installation checklist (page 145).

  • Page 149: Switching Off The Drive

    Start-up 149 Action Check that parameter 95.09 Switch fuse controller is set to Disabled. Drives with a brake chopper (option +D150): See chapter Resistor braking (page 269). Drives with a sine output filter (option +E206): Check that bit 1 of parameter 95.15 Special HW settings is activated.

  • Page 151: Fault Tracing

    Fault tracing 151 Fault tracing Contents of this chapter This chapter describes the fault tracing possibilities of the drive. Control unit LEDs Color Indication BATT OK Green Battery voltage of the real-time clock is OK (higher than 2.8 V). When the LED is not lit, •battery voltage is below 2.8 V, •the battery is missing, or •the control unit is not powered.

  • Page 152: Warning And Fault Messages

    152 Fault tracing Location Indication Control panel Continuous green The unit is functioning normally. Flickering green Data is transferred between the PC and the unit through the USB connection of the control panel. Blinking green There is an active warning in the unit. Continuous red There is an active fault in the unit.

  • Page 153: Maintenance

    This chapter contains maintenance instructions. Maintenance intervals The table below shows the maintenance tasks which can be done by the end user. The complete maintenance schedule is available on the Internet (www.abb.com/drivesservices). For more information, consult your local ABB Service representative (www.abb.com/searchchannels).
  • Page 154 154 Maintenance Years from start-up Maintenance task/object … Cooling Supply/Inverter module main cooling fan Supply/Inverter module circuit board compart- ment fan LCL filter cooling fan (50 Hz) LCL filter cooling fan (60 Hz) Sine filter cooling fan Door fan Other cabinet cooling fans (50 Hz) Other cabinet cooling fans (60 Hz) Batteries Control unit battery...
  • Page 155 Maintenance 155 Note: • 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. • Long term operation near the specified maximum ratings or ambient conditions may require shorter maintenance intervals for certain components.

  • Page 156: Cabinet

    156 Maintenance Cabinet Cleaning the interior of the cabinet ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. WARNING! Use a vacuum cleaner with antistatic hose and nozzle, and wear a grounding wristband.

  • Page 157: Replacing The Inlet Door Filters (Ip54)

    Maintenance 157 Replacing the inlet door filters (IP54) ￭ 1. Stop the drive and do the steps in section Electrical safety precautions (page 18) before you start the work. 2. Remove the fasteners at the top of the grating. 3. Lift the grating and pull it away from the door. 4.

  • Page 158: Power Connections And Quick Connectors

    158 Maintenance Power connections and quick connectors Retightening the power connections ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work.

  • Page 159: Fans

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

  • Page 160: Replacing R8I Module Cooling Fan (Speed-Controlled Version)

    160 Maintenance Replacing R8i module cooling fan (speed-controlled version) ￭ The module is equipped with a fan unit that contains two cooling fans. WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work.

  • Page 161: Replacing R8I Module Cooling Fan (Direct-On-Line Version)

    Maintenance 161 Replacing R8i module cooling fan (direct-on-line version) ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. If you are not a qualified electrical professional, do not do installation or maintenance work. WARNING! Use the required personal protective equipment.
  • Page 162 162 Maintenance...

  • Page 163: Replacing The Fan Of The Lcl Filter (Blcl-1X-X)

    Maintenance 163 Replacing the fan of the LCL filter (BLCL-1x-x) ￭ WARNING! Obey the safety instructions given in ACS880 multidrive cabinets and modules safety instructions (3AUA0000102301 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.

  • Page 164: Replacing The Fan Of The Lcl Filter (Blcl-2X-X)

    164 Maintenance Replacing the fan of the LCL filter (BLCL-2x-x) ￭ WARNING! Obey the safety instructions given in ACS880 multidrive cabinets and modules safety instructions (3AUA0000102301 [English]). If you ignore the safety instructions, injury or death, or damage to the equipment can occur.

  • Page 165: Replacing The Circuit Board Compartment Fan

    Maintenance 165 Replacing the circuit board compartment fan ￭ Frame R8i modules are equipped with a fan blowing air through the circuit board compartment. The fan is accessible from the front of the module. WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur.

  • Page 166: Replacing The Cooling Fan In The Auxiliary Control Cubicle

    166 Maintenance 8. Put the fan onto the threaded studs on the fan holder with the airflow direction arrow pointing towards the fan holder. 9. Install and tighten the four nuts removed earlier. 10. Connect the fan cable. 11. Align and push the fan holder into the module. 12.

  • Page 167: Replacing The Cooling Fan In The Incoming Cubicle

    Maintenance 167 Replacing the cooling fan in the incoming cubicle ￭ WARNING! Obey the safety instructions of the drive. If you ignore them, injury or death, or damage to the equipment can occur. 1. Stop the drive and do the steps in section Electrical safety precautions (page 18) before you start the work.

  • Page 168: Replacing The Brake Chopper And Resistor Cubicle Fans (Options +D150 And +D151)

    168 Maintenance 7. Lift the fan off. 8. Install the new fan in reverse order. Replacing the brake chopper and resistor cubicle fans (options +D150 ￭ and +D151) See chapter Resistor braking (page 269).

  • Page 169: Supply And Inverter Modules

    Maintenance 169 Supply and inverter modules Replacing a supply or inverter module ￭ WARNING! Make sure the replacement module has exactly the same type code as the old module. Follow the module extraction and insertion procedures in chapter Electrical installation. Cleaning the heatsink ￭...
  • Page 170 170 Maintenance 1. Stop the drive and do the steps in section Electrical safety precautions (page 18) before you start the work. 2. Remove the shrouding above the module bay (in front of the DC fuses). 3. Remove the DC fuses and the busbar assembly connecting the fuses to the inverter module.

  • Page 171: Returning The Module

    Maintenance 171 11. Reset all faults and start the drive. 12. If the Safe torque off (STO) function is in use, perform an acceptance test. See the STO instructions. The maximum current is now automatically limited according to the new inverter configuration. A mismatch between the number of detected modules and the value set in 95.13 will generate a fault.

  • Page 172: Lcl Filter

    172 Maintenance LCL filter Replacing the LCL filter ￭ Refer to the drawings below. WARNING! Obey the safety instructions. If you ignore them, injury or death, or damage to the equipment can occur.
  • Page 173 Maintenance 173 WARNING! • Do not use the module extraction/installation ramp with plinth heights which exceeds the maximum allowed height. • Secure the module extraction/installation ramp carefully. • Push the module into the cabinet and pull it from the cabinet carefully preferably with help from another person.
  • Page 174 174 Maintenance Note: As an alternative to using the extraction/installation ramp, a lifter is available from ABB Service. For more information, contact ABB Service, or see Lifter for air-cooled drive modules user's guide (3AXD50000332588 [English]). 1. Stop the drive (if running) and do the steps in section...
  • Page 175 Maintenance 175...

  • Page 176: Capacitors

    Capacitor failure is usually followed by damage to the unit and an input cable fuse failure, or a fault trip. If you think that any capacitors in the drive have failed, contact ABB. Reforming the capacitors ￭...

  • Page 177: Fuses

    Maintenance 177 Fuses Replacing the AC and DC fuses in cabinet ￭ This procedure instructs how to replace the drive AC and DC fuses inside the cabinet. The location of the fuses vary depending on the drive type and options. Locate the fuses to be replaced using the delivery-specific layout drawings and circuit diagrams.

  • Page 178: Control Panel

    178 Maintenance 7. Tighten the nuts to torque as follows: • Bussmann fuses: 50 N·m (37 lbf·ft) • Mersen (Ferraz-Shawmut): 46 N·m (34 lbf·ft) • Other: Refer to the fuse manufacturer’s instructions. 8. Reinstall the shroud and close the door. Control panel For detailed information on the control panel, see ACx-AP-x assistant control panels user’s manual...
  • Page 179 Maintenance 179 5. Put the lid back and tighten it by turning it clockwise. 6. Dispose of the old battery according to local disposal rules or applicable laws.

  • Page 180: Control Units

    180 Maintenance Control units BCU control unit types ￭ There are three variants of the BCU control unit used in ACS880 drives: BCU-02, BCU-12 and BCU-22. These have a different number of converter module connections (2, 7 and 12 respectively) but are otherwise identical. The three BCU types are interchangeable as long as the number of connections is sufficient.

  • Page 181: Functional Safety Components

    Note that some of the components may already have been renewed earlier, restarting their mission time. The remaining mission time of the whole circuit is however determined by its oldest component. Contact your local ABB service representative for more information.

  • Page 183: Technical Data

    The nominal ratings for the drives with 50 Hz and 60 Hz supply are given below. The symbols are described below the table. Output ratings Input rating No-overload use Light-overload use Heavy-duty use ACS880-37-… = 400 V 0450A-3 – – – 0620A-3 –...

  • Page 184: 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 185: Derating

    1 percentage point for every added 100 m (328 ft). For example, the derating factor for 1500 m (4921 ft) is 0.95. For altitudes above 2000 m (6562 ft), contact ABB. If surrounding air temperature is below +40 °C, the derating can be reduced by 1.5 percentage points for every 1 °C reduction in temperature.

  • Page 186: Switching Frequency Derating

    Derating factor 0.80 For a more accurate derating, use the DriveSize PC tool. Switching frequency derating Switching frequencies other than default can require output current derating. Contact ABB for more information. Output frequency derating Motor operation above 150 Hz can require type-specific output current derating. Contact...

  • Page 187: Derating For Output Voltage Boosting

    This drawing shows the required derating. It is valid for all supply voltage ranges. Example: P for ACS880-37-1010A-5 is 710 kW. The supply voltage (U) is 450 V. -> U / = 450 V / 500 V = 0.9. -> P / P = 0.9 ->...

  • Page 188: Frame Sizes And Power Module Types

    188 Technical data Frame sizes and power module types Supply module(s) used LCL filter(s) used Inverter modules used ACS880-37-… Frame size Type Type Type ACS880-104-… ACS880-104-… = 400 V 0450A-3 1×R8i+1×R8i 0470A-3 BLCL-13-5+V991 0470A-3+E205 0620A-3 1×R8i+1×R8i 0640A-3 BLCL-13-5+V991 0640A-3+E205 0870A-3 1×R8i+1×R8i...

  • Page 189: Fuses

    Technical data 189 Fuses AC fuses ￭ Notes: • Fuses with higher current rating than the recommended ones must not be used. • Fuses from other manufacturers can be used if they meet the ratings and the melting curve of the fuse does not exceed the melting curve of the fuse mentioned in the table. Ultrarapid (aR) AC fuses Bussmann (IEC/UL) Mersen/Ferraz Shawmut (IEC only)

  • Page 190: Dc Fuses

    190 Technical data Ultrarapid (aR) AC fuses Bussmann (IEC/UL) Mersen/Ferraz Shawmut (IEC only) Input Clearing ACS880- Rated current Clearing Rated Rated t at 37-… current t at voltage voltage rated Type Type 660 V voltage 2500 170M7063 7800000 – – –...

  • Page 191: Fuses On Cvar Varistor Board

    Technical data 191 DC fuses ACS880- Clearing I t at Rated current Rated voltage 37-… 660 V Bussmann type 0950A-7 1000 170M6548 1100 2150000 1130A-7 1100 170M6549 1000 2800000 1450A-7 1000 170M6548 1100 2150000 1680A-7 1100 170M6549 1000 2800000 1950A-7 1100 170M6549 1000...

  • Page 192: Cooling Data, Noise

    192 Technical data Cooling data, noise Air flow Heat dissipation Noise ACS880-37-… /min dB(A) = 400 V 0450A-3 2860 1680 0620A-3 2860 1680 0870A-3 2860 1680 1110A-3 5720 3370 1210A-3 5720 3370 1430A-3 5720 3370 1700A-3 5720 3370 2060A-3 8580...

  • Page 193: Sine Output Filter Data

    The table shows the types and technical data of the filters and filter cubicles used. The standard filters listed require no current derating. For availability of sine output filters for other drive types, contact your local ABB representative. Sine filter(s) used...

  • Page 194: Input Cable Sizes

    194 Technical data Input cable sizes The table below gives copper and aluminum cable types with concentric copper shield for nominal current. ACS880-37-… Al cable size Cu cable size Cu cable size AWG/kcmil = 400 V 0450A-3 2 × (3 × 240 + 72 Cu) 2 ×...
  • Page 195 Technical data 195 2) The cable sizing is based on NEC Table 310-15(B)(16) for copper wires, 75 °C (167 °F) wire insulation at 40 °C (104 °F) ambient temperature. Not more than three current-carrying conductors in raceway or cable or earth (directly buried). For other conditions, size the cables according to local safety regulations, appropriate input voltage and the load current of the drive.

  • Page 196: Output Cable Sizes

    Note: If the drive is not equipped with a common motor terminal cubicle (option +H359), common output terminals (option +H366) or sine filter (option +E206), each inverter module of the drive is to be individually cabled to the motor. ACS880-37-… Al cable size Cu cable size...

  • Page 197: Terminal And Lead-Through Data For The Power Cables

    Technical data 197 ACS880-37-… Al cable size Cu cable size Cu cable size AWG/kcmil 3310A-7 12 × (3 × 300 + 88 Cu) 12 × (3 × 240 + 120) 12 × (3 × 500 kcmil) XLPE-insulated only 1) The cable sizing is based on max. 9 cables laid on a cable ladder side by side, three ladder type trays one on top of the other, ambient temperature 30 °C, PVC insulation, surface temperature 70 °C (IEC/EN 60204-1 and IEC 60364-5-52/2001).

  • Page 198: Motor Connection Data

    Note: Longer cables cause a motor voltage decrease which limits the available motor power. The decrease depends on the motor cable length and characteristics. Contact ABB for more information. Also note that a sine filter (optional) at the drive output also causes a voltage decrease.

  • Page 199: Efficiency

    • Maximum long-term tensile load: 1 N (3.6 ozf) • Flexing: Max. 1000 cycles ABB drive products in general utilize 5 and 10 MBd (megabaud) optical components from Avago Technologies’ Versatile Link range. Note that the optical component type is not directly related to the actual communication speed.

  • Page 200: Ambient Conditions

    200 Technical data Ambient conditions Environmental limits for the drive are given below. The drive is to be used in a heated, indoor, controlled environment. Operation Storage Transportation installed for stationary in the protective package in the protective package Air temperature 0 …...

  • Page 201: Package

    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 202: Markings

    202 Technical data Standard Information IEC 60204-1:2005 + Safety of machinery. Electrical equipment of machines. Part 1: General require- A1:2008 ments. EN 60204-1:2006 + AC:2010 IEC/EN 61439-1:2009 Low-voltage switchgear and controlgear assemblies -- Part 1: General rules EMC performance IEC/EN 61800-3:2004 Adjustable speed electrical power drive systems.

  • Page 203: Emc Compliance (Iec/En 61800-3)

    Technical data 203 RCM mark Product complies with Australian and New Zealand requirements specific to EMC, telecommunica- tions and electrical safety. For fulfilling the EMC requirements, see the additional information con- cerning the drive EMC compliance (IEC/EN 61800-3). KC mark Product complies with Korea’s product safety requirements for electrical and electronic equipment and components that utilize power from 50…1000 V AC.

  • Page 204: Category C3

    204 Technical data WARNING! The drive may cause radio interference if used in a residential or domestic environment. The installer is required to take measures to prevent interference, in addition to the requirements for CE compliance listed above, if necessary. WARNING! Do not install a drive equipped with the C2 EMC filter on IT (ungrounded) systems.

  • Page 205: Category C4

    Technical data 205 Category C4 ￭ The drive complies with the C4 category with these provisions: 1. It is ensured that no excessive emission is propagated to neighboring low-voltage networks. In some cases, the natural suppression in transformers and cables is sufficient. If in doubt, the supply transformer with static screening between the primary and secondary windings can be used.
  • Page 206 206 Technical data...
  • Page 207 Technical data 207...

  • Page 208: Ul And Csa Checklist

    The fuses are listed elsewhere in this chapter. • The drive provides motor overload protection. This feature is not enabled when the drives leaves the ABB factory. For enabling this motor overload protection, see the firmware manual. • The drive overvoltage category according to IEC 60664-1 is III, except for auxiliary power...

  • Page 209: Tightening Torques

    Technical data 209 Tightening torques Unless a tightening torque is specified in the text, the following torques can be used. Electrical connections ￭ Size Torque Strength class 0.5 N·m (4.4 lbf·in) 4.6...8.8 1 N·m (9 lbf·in) 4.6...8.8 4 N·m (35 lbf·in) 9 N·m (6.6 lbf·ft) 22 N·m (16 lbf·ft) 42 N·m (31 lbf·ft)

  • Page 210: Cybersecurity Disclaimer

    ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized...

  • Page 211: Dimensions

    • Not all possible configurations are presented. For information on unlisted configurations, contact ABB. • The data given is preliminary. ABB reserves the right to modify the design at any time without notice. Consult ABB for up-to-date, drive-specific information. The tables are followed by selected dimension drawing examples.

  • Page 212: Dimension Tables

    2400 + 1000 4800 2400 1) 400 mm with ACS880-37-0450A-3, -0420-5, -0320A-7 and -0390A-7, 1000 mm with other types. 2) The number of brake choppers depends on required braking power. See chapter Resistor braking. ACS880-37-1110A-3, -1010A-5, -1110A-5, -0660A-7, -0770A-7, -0950A-7, -1130A-7...
  • Page 213 Dimensions 213 ACS880-37-1110A-3, -1010A-5, -1110A-5, -0660A-7, -0770A-7, -0950A-7, -1130A-7 2500 4900 2400 3400 1000 5800 2400 3400 3400 3700 3700 3400 1000 4600 1200 2400 6000 3600 2500 6100 3600 3400 1000 7000 3600 1) The number of brake choppers depends on required braking power. See chapter Resistor braking.
  • Page 214 3600 2800 6400 3600 2700 6300 3600 2900 6500 3600 1) Double-busbar version with ACS880-37-1430A-3, -1700A-3, -1530A-5 2) ACS880-37-1210A-3 only 3) The number of brake choppers depends on required braking power. See chapter Resistor braking. 3×R8i+3×R8i Common Auxiliary Supply Incoming...
  • Page 215 3800 3800 3400 3400 3700 3700 3800 3800 4000 4000 1) 300 mm double-busbar version with ACS880-37-1450A-7 and -1680A-7. 600 mm with ACS880-37-2530A-3+H353 (top exit). 400 mm with other types. 4×R8i+4×R8i Auxili- Com- Incom- Supply Supply Inverter Inverter ary con-...

  • Page 216: Weights

    1000 4200 + 2200 6400 1) 1000 mm with UL Listed (+C129) and CSA Approved (+C134) units, otherwise 600 mm. Weights ￭ The table below lists the approximate basic weights. Weight ACS880-37... 0450A-3 0420A-5 0320A-7 0620A-3 0570A-5 0390A-7 1180 2600...

  • Page 217: Dimension Drawing Examples

    Dimensions 217 204 Dimensions Dimension drawing examples ￭  Dimension drawing examples Frame 1×R8i+1×R8i Frame 1×R8i + 1×R8i...

  • Page 218: Frame 1×R8I+1×R8I, Top Cable Entry/Exit (+H351+H353)

    218 Dimensions Dimensions 205 Frame 1×R8i + 1×R8i, top cable entry/exit (+H351+H353) Frame 1×R8i+1×R8i, top cable entry/exit (+H351+H353)

  • Page 219: Frame 1×R8I+1×R8I With Brake Choppers And Resistors (+D150+D151)

    206 Dimensions Frame 1×R8i + 1×R8i with brake choppers and resistors (+D150+D151) Dimensions 219 Frame 1×R8i+1×R8i with brake choppers and resistors (+D150+D151)

  • Page 220: Frame 1×R8I+1×R8I With Sine Output Filter (+E206)

    Dimensions 207 Frame 1×R8i + 1×R8i with sine output filter (+E206) 220 Dimensions Frame 1×R8i+1×R8i with sine output filter (+E206)

  • Page 221: Frame 2×R8I+2×R8I (Eg. Acs880-37-1110A-3), Ip22

    208 Dimensions Frame 2×R8i + 2×R8i (eg. ACS880-1737-1110A-3), IP22 Dimensions 221 Frame 2×R8i+2×R8i (eg. ACS880-37-1110A-3), IP22...

  • Page 222: Frame 2×R8I+2×R8I (Eg. Acs880-37-1210A-3), Ip54

    Dimensions 209 Frame 2×R8i + 2×R8i (eg. ACS880-1737-1210A-3), IP54 222 Dimensions Frame 2×R8i+2×R8i (eg. ACS880-37-1210A-3), IP54...

  • Page 223: Frame 2×R8I+2×R8I With Main Breaker (+F255) And Common Motor Terminal Cubicle (+H359), 1/2

    210 Dimensions Frame 2×R8i + 2×R8i with main breaker (+F255) and common motor terminal cubicle Dimensions 223 (+H359), 1/2 Frame 2×R8i+2×R8i with main breaker (+F255) and common motor terminal cubicle (+H359), 1/2...

  • Page 224: Frame 2×R8I+2×R8I With Main Breaker (+F255) And Common Motor Terminal Cubicle (+H359), 2/2

    224 Dimensions Frame 2×R8i+2×R8i with main breaker (+F255) and common motor terminal cubicle (+H359), 2/2...

  • Page 225: Frame 2×R8I+2×R8I With Main Breaker (+F255) And Top Entry/Top Exit (+H351+H353), 1/2

    Dimensions 225 212 Dimensions Frame 2×R8i+2×R8i with main breaker (+F255) and top entry/top exit (+H351+H353), Frame 2×R8i + 2×R8i with main breaker (+F255) and top entry/top exit (+H351+H353),...

  • Page 226: Frame 2×R8I+2×R8I With Main Breaker (+F255) And Top Entry/Top Exit (+H351+H353), 2/2

    226 Dimensions Frame 2×R8i+2×R8i with main breaker (+F255) and top entry/top exit (+H351+H353),...

  • Page 227: Frame 3×R8I+3×R8I, 1/2

    Dimensions 227 214 Dimensions Frame 3×R8i+3×R8i, 1/2 Frame 3×R8i + 3×R8i, 1/2...

  • Page 228: Frame 3×R8I+3×R8I, 2/2

    Dimensions 215 228 Dimensions Frame 3×R8i + 3×R8i, 2/2 Frame 3×R8i+3×R8i, 2/2...

  • Page 229: Frame 3×R8I+3×R8I With Common Motor Terminal Cubicle (+H359), 1/2

    Dimensions 229 216 Dimensions Frame 3×R8i+3×R8i with common motor terminal cubicle (+H359), 1/2 Frame 3×R8i + 3×R8i with common motor terminal cubicle (+H359), 1/2...

  • Page 230: Frame 3×R8I+3×R8I With Common Motor Terminal Cubicle (+H359), 2/2

    Dimensions 217 230 Dimensions Frame 3×R8i + 3×R8i with common motor terminal cubicle (+H359), 2/2 Frame 3×R8i+3×R8i with common motor terminal cubicle (+H359), 2/2...

  • Page 231: Dimensions Of Empty Cubicles (Options +C199, +C200, +C201)

    Dimensions 231 Dimensions of empty cubicles (options +C199, +C200, +C201) IP22/IP42...
  • Page 232 232 Dimensions IP54...

  • Page 233: Location And Size Of Input Terminals

    Dimensions 233 218 Dimensions Location and size of input terminals 218 Dimensions Location and size of input terminals Note: See the dimension tables as to which incoming cubicles are used with which drive Location and size of input terminals type and options. ...

  • Page 234: Frame 2×R8I+2×R8I With Main Switch/Disconnector (400 Mm), Bottom Cable Entry (+H353)

    234 Dimensions Dimensions 219  Frame 2×R8i + 2×R8i with main switch/disconnector (400 mm), Frame 2×R8i+2×R8i with main switch/disconnector (400 mm), bottom ￭ bottom cable entry cable entry (+H353) 220 Dimensions  Frame 2×R8i + 2×R8i with main switch/disconnector (600 mm), Frame 2×R8i+2×R8i with main switch/disconnector (600 mm), bottom ￭...

  • Page 235: Units With Main Breaker (600 Mm, +F255), Bottom Cable Entry

    Dimensions 235 Dimensions 221 Dimensions 221  Units with main breaker (600 mm), bottom cable entry  Units with main breaker (600 mm), bottom cable entry Units with main breaker (600 mm, +F255), bottom cable entry ￭  Units with main breaker (600 mm), top cable entry Units with main breaker (600 mm, +F255), top cable entry (+H351) ￭...

  • Page 236: Units With Main Breaker (1000 Mm), Top Cable Entry

    236 Dimensions Units with main breaker (1000 mm), top cable entry ￭...

  • Page 237: Units With Main Breaker (1000 Mm), Bottom Cable Entry (+H350)

    Dimensions 237 Units with main breaker (1000 mm), bottom cable entry (+H350) ￭ Location and size of output terminals Units without common motor terminal cubicle ￭ Frame 1×R8i+1×R8i (without sine output filter) See sections Frame 1×R8i+1×R8i, bottom cable entry (page 233) Frame 1×R8i+1×R8i, top cable entry (+H351) (page 233)

  • Page 238: Inverter Module Cubicle With Two R8I Modules, Bottom Cable Exit

    238 Dimensions Inverter module cubicle with two R8i modules, bottom cable exit...

  • Page 239: Inverter Module Cubicle With Two R8I Modules, Top Cable Exit

    Dimensions 239 Inverter module cubicle with two R8i modules, top cable exit...

  • Page 240: Inverter Module Cubicle With Three R8I Modules, Bottom Cable Exit

    240 Dimensions Inverter module cubicle with three R8i modules, bottom cable exit...

  • Page 241: Inverter Module Cubicle With Three R8I Modules, Top Cable Exit

    Dimensions 241 Inverter module cubicle with three R8i modules, top cable exit...

  • Page 242: Brake Chopper Cubicle

    242 Dimensions Brake chopper cubicle...

  • Page 243: Sine Filter Cubicle, 1000 Mm, Bottom Cable Exit

    Dimensions 243 Sine filter cubicle, 1000 mm, bottom cable exit...

  • Page 244: Sine Filter Cubicle, 1000 Mm, Top Cable Exit

    244 Dimensions Sine filter cubicle, 1000 mm, top cable exit...

  • Page 245: Units With Common Motor Terminal Cubicle (+H359)

    Dimensions 245 Units with common motor terminal cubicle (+H359) ￭ Cubicle width 300 mm, bottom cable exit...

  • Page 246: Cubicle Width 300 Mm, Top Cable Exit

    246 Dimensions Cubicle width 300 mm, top cable exit...

  • Page 247: Cubicle Width 400 Mm, Bottom Cable Exit

    Dimensions 247 Cubicle width 400 mm, bottom cable exit...

  • Page 248: Cubicle Width 400 Mm, Top Cable Exit

    248 Dimensions Cubicle width 400 mm, top cable exit...

  • Page 249: Cubicle Width 600 Mm, Bottom Cable Exit

    Dimensions 249 Cubicle width 600 mm, bottom cable exit...

  • Page 250: Cubicle Width 600 Mm, Top Cable Exit

    250 Dimensions Cubicle width 600 mm, top cable exit...

  • Page 251: The Safe Torque Off Function

    The Safe torque off function 251 The Safe torque off function Contents of this chapter This chapter describes the Safe torque off (STO) function of the drive and gives instructions for its use. Description WARNING! In case of parallel-connected drives or dual-winding motors, the STO must be activated on each drive to remove the torque from the motor.

  • Page 252: Compliance With The European Machinery Directive

    252 The Safe torque off function Standard Name IEC 61000-6-7:2014 Electromagnetic compatibility (EMC) – Part 6-7: Generic standards – Im- munity requirements for equipment intended to perform functions in a safety-related system (functional safety) in industrial locations IEC 61326-3-1:2017 Electrical equipment for measurement, control and laboratory use – EMC requirements –...

  • Page 253: Wiring

    The Safe torque off function 253 Wiring For the electrical specifications of the STO connection, see the technical data of the control unit. Activation switch ￭ In the wiring diagrams, the activation switch has the designation [K]. This represents a component such as a manually operated switch, an emergency stop push button switch, or the contacts of a safety relay or safety PLC.

  • Page 254: Dual-Channel Connection With Internal Power Supply

    254 The Safe torque off function Dual-channel connection with internal power supply ￭ XSTO +24 V SGND XSTO OUT STO IN (X52) 24VDC CH1 SGND GND CH1 24VDC CH2 SGND GND CH2 STO IN (X52) STO OUT (X51) 24VDC CH1 24VDC CH1 GND CH1 GND CH1...

  • Page 255: Single-Channel Connection Of Activation Switch

    The Safe torque off function 255 Single-channel connection of activation switch ￭ +24 V SGND Note: •Both STO inputs (IN1, IN2) must be connected to the activation switch. Otherwise, no SIL/PL classification is given. •Pay special attention to avoiding any potential failure modes for the wiring. For example, use shielded cable. For measures for fault exclusion of wiring, see eg.

  • Page 256: Multiple Drives

    256 The Safe torque off function Multiple drives ￭ Internal power supply XSTO +24 V SGND XSTO SGND XSTO SGND Drive Control unit Activation switch * Terminal designation may vary depending on drive type...

  • Page 257: External Power Supply

    The Safe torque off function 257 External power supply 24 V DC – XSTO +24 V SGND XSTO SGND XSTO SGND Drive Control unit Activation switch * Terminal designation may vary depending on drive type...

  • Page 258: Operation Principle

    258 The Safe torque off function Operation principle 1. The Safe torque off activates (the activation switch is opened, or safety relay contacts open). 2. The STO inputs of the drive control unit de-energize. 3. The control unit cuts off the control voltage from the output IGBTs. 4.

  • Page 259: Start-Up Including Validation Test

    The Safe torque off function 259 Start-up including validation test To ensure the safe operation of a safety function, validation is required. The final assembler of the machine must validate the function by performing a validation test. The test must be performed •...
  • Page 260 260 The Safe torque off function Action Test the operation of the STO function when the motor is stopped. •Give a stop command for the drive (if running) and wait until the motor shaft is at a standstill. Make sure that the drive operates as follows: •Open the STO circuit.

  • Page 261: Use

    The Safe torque off function 261 1. Open the activation switch, or activate the safety functionality that is wired to the STO connection. 2. The STO inputs on the drive control unit de-energize, and the control unit cuts off the control voltage from the output IGBTs.
  • Page 262 262 The Safe torque off function • If a running drive is stopped by using the Safe torque off function, the drive will cut off the motor supply voltage and the motor will coast to a stop. If this causes danger or is not otherwise acceptable, stop the drive and machinery using the appropriate stop mode before activating the Safe torque off function.

  • Page 263: Maintenance

    If any wiring or component change is needed after start up, or the parameters are restored, do the test given in section Validation test procedure (page 259). Use only spare parts approved by ABB. Record all maintenance and proof test activities in the machine logbook. Competence ￭...

  • Page 264: Fault Tracing

    See the firmware manual of the drive control program for the indications generated by the drive, and for details on directing fault and warning indications to an output on the control unit for external diagnostics. Any failures of the Safe torque off function must be reported to ABB.

  • Page 265: Safety Data

    The Safe torque off function 265 Safety data The safety data for the Safe torque off function is given below. Note: The safety data is calculated for redundant use, and does not apply if both STO channels are not used. MTTF SIL/ Frame size...

  • Page 266: Abbreviations

    Mission time: the period of time covering the intended use of the safety function/device. After the mission time elapses, the safety device must be replaced. Note that any T values given cannot be regarded as a guarantee or warranty. TÜV certificate ￭ The TÜV certificate is available on the Internet at www.abb.com/drives/documents.

  • Page 267: Declaration Of Conformity

    The Safe torque off function 267 Declaration of conformity ￭...
  • Page 268 268 The Safe torque off function...

  • Page 269: Resistor Braking

    Resistor braking 269 Resistor braking Contents of this chapter This chapter describes how to select, protect and wire brake choppers and resistors. The chapter also contains the related technical data. Operation principle The brake chopper handles the energy generated by a decelerating motor. The extra energy increases the DC link voltage.

  • Page 270: Factory-Installed Brake Choppers And Resistors

    270 Resistor braking Factory-installed brake choppers and resistors The following brake choppers (option +D150) and resistors (+D151) are available for the drive as factory-installed. It is also possible to use option +D150 with a custom resistor assembly. Technical data Definitions ￭...

  • Page 271: Planning The Braking System

    Resistor braking 271 Planning the braking system Verifying the load capacity of the braking equipment ￭ 1. Calculate the maximum power generated by the motor during braking (P 2. Ensure that the maximum power rating of the braking equipment is equal to or greater than P The P values specified in the ratings table are for the reference braking cycle...

  • Page 272: Selecting And Routing The Cables Of A Custom Resistor

    IGBT semiconductors of the brake chopper. Note: ABB has not verified that the EMC requirements are fulfilled with custom brake resistors and cabling. The customer must consider the EMC compliance of the complete installation.

  • Page 273: Placing The Brake Resistor

    Resistor braking 273 Placing the brake resistor ￭ Install the resistor assembly outside the drive in a place where it is able to cool effectively. Arrange the cooling of the resistor in a way that: • no danger of overheating is caused to the resistor or nearby materials, and •...

  • Page 274: Electrical Installation Of Custom Brake Resistors

    274 Resistor braking Electrical installation of custom brake resistors Connection diagram ￭ Brake chopper cubicle t° Brake resistor cubicle Connection procedure ￭ WARNING! Obey the instructions in chapter Safety instructions. If you ignore them, injury or death, or damage to the equipment can occur. •...

  • Page 275: Brake System Start-Up

    the work. • Connect the resistor cable at the resistor end only. If a shielded three-conductor cable is used, cut off the third conductor. Ground the twisted shield of the cable as well as Resistor braking 275 any separate PE conductor (if present). •...

  • Page 276: Maintenance

    276 Resistor braking Maintenance Replacing the brake resistor cabinet fan ￭ WARNING! Wear protective gloves and long sleeves. Some parts have sharp edges. 1. Stop the drive and do the steps in section Electrical safety precautions (page 18) before you start the work. 2.
  • Page 277 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 278 3AXD50000020437C © Copyright 2021 ABB. All rights reserved. Specifications subject to change without notice.

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