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Resistor braking   211

14

Resistor braking

What this chapter contains

This chapter describes how to select, protect and wire brake choppers and resistors. 
The chapter also contains technical data.

Operation principle and hardware description

Frames R1 to R4 have a built-in brake chopper as standard. Frames R5 and up can 
be equipped with optional built-in brake chopper (+D150). Brake resistors are 
available as add-on kits.

The brake chopper handles the energy generated by a decelerating motor. The 
chopper connects the brake resistor to the intermediate DC circuit whenever the 
voltage in the circuit exceeds the limit defined by the control program. Energy 
consumption by the resistor losses lowers the voltage until the resistor can be 
disconnected.

Planning the braking system

„

Selecting the brake circuit components

1. Calculate the maximum power generated by the motor during braking (

P

max

).

2. Select a suitable drive, brake chopper and brake resistor combination for the 

application from the rating table on page 

217

. The braking power of the chopper

 

must be greater or equal than the maximum power generated by the motor during 
the braking. 

ACS880-01 HW.book  Page 211  Monday, July 1, 2013  4:51 PM

Summary of Contents for ACS880-01 Series

Page 1: ...ABB industrial drives Hardware manual ACS880 01 drives 0 55 to 250 kW 0 75 to 350 hp ACS880 01 HW book Page 1 Monday July 1 2013 4 51 PM...

Page 2: ...R1 to R3 3AUA0000085966 ACS880 01 quick installation guide for frames R4 and R5 3AUA0000099663 ACS880 01 quick installation guide for frames R6 to R9 3AUA0000099689 ACS880 01 cabinet installation supp...

Page 3: ...Table of contents Mechanical installation Start up Hardware manual ACS880 01 drives 0 55 to 250 kW 0 75 to 350 hp 3AUA0000078093 Rev G EN EFFECTIVE 2013 07 01 2013 ABB Oy All Rights Reserved ACS880 0...

Page 4: ...ACS880 01 HW book Page 4 Monday July 1 2013 4 51 PM...

Page 5: ...manuals 22 Categorization by frame size and option code 22 Quick installation start up and operating flowchart 23 Terms and abbreviations 24 Safety data SIL PL 25 3 Operation principle and hardware d...

Page 6: ...ts table 55 Additional requirements for ABB motors of types other than M2_ M3_ M4_ HX_ and AM_ 58 Additional requirements for ABB high output and IP23 motors 59 Additional requirements for non ABB hig...

Page 7: ...ing the motor power supply from direct on line to drive 77 Protecting the contacts of relay outputs 77 Connecting a motor temperature sensor to the drive I O 79 6 Electrical installation What this cha...

Page 8: ...r contains 121 Maintenance intervals 121 Preventive maintenance table 122 Heatsink 123 Fans 123 Replacing the main cooling fan of frames R1 to R3 124 Replacing the auxiliary cooling fan of IP55 frames...

Page 9: ...nal and lead through data for the power cables 160 IEC 160 US 161 UL listed cable lugs and tools 162 Terminal data for the control cables 162 Electrical power network specification 163 Motor connectio...

Page 10: ...tion What this chapter contains 197 Description 197 Compliance with the European Machinery Directive 198 Wiring 198 Activation switch 198 Cable types and lengths 198 Single drive internal power supply...

Page 11: ...atings 217 Degree of protection of JBR SACE and SAFUR resistors 219 Terminals and cable lead through data 219 15 Common mode du dt and sine filters What this chapter contains 221 Common mode filters 2...

Page 12: ...12 ACS880 01 HW book Page 12 Monday July 1 2013 4 51 PM...

Page 13: ...conditions which can result in serious injury or death and or damage to the equipment and advise on how to avoid the danger The following warning symbols are used in this manual Electricity warning wa...

Page 14: ...rcuits Externally supplied control circuits may cause dangerous voltages inside the drive even when the main power on the drive is switched off Do not make any insulation or voltage withstand tests on...

Page 15: ...rbances In addition connect the cable shields to protective earth PE in order to meet safety regulations Do not install a drive with EMC filter option E200 or E202 on an ungrounded power system or a h...

Page 16: ...tage on the drive power terminals according to step 1 or 2 or if possible according to the both steps 1 Disconnect the motor from the drive with a safety switch or by other means Check by measuring th...

Page 17: ...The drive is heavy and its center of gravity is high An overturning unit can cause physical injury Beware of hot surfaces Some parts such as heatsinks of power semiconductors remain hot for a while a...

Page 18: ...ed by the drive The drive can be adjusted to operate the motor at speeds above and below the speed provided by connecting the motor directly to the power line Do not activate any automatic fault reset...

Page 19: ...t motor drives WARNING Do not run the motor over the rated speed Motor overspeed leads to overvoltage which may damage or explode the capacitors in the intermediate circuit of the drive ACS880 01 HW b...

Page 20: ...20 Safety instructions ACS880 01 HW book Page 20 Monday July 1 2013 4 51 PM...

Page 21: ...rical schematic symbols The manual is written for readers worldwide Both SI and imperial units are shown Contents of the manual This manual contains the instructions and information for the basic driv...

Page 22: ...on its implementing Resistor braking describes selection protection and wiring of brake choppers and resistors The chapter also contains technical data Common mode du dt and sine filters describes se...

Page 23: ...es and equipment are present and correct Mount the drive Mechanical installation page 41 or 43 If the drive has been non operational for more than one year the converter DC link capacitors need to be...

Page 24: ...Optional TTL absolute encoder interface module FEN 21 Optional resolver interface module FEN 31 Optional HTL incremental encoder interface module FOA 01 Optional optical DDCS communication adapter mod...

Page 25: ...life units the number of dangerous undetected failures during a particular measurement interval under stated conditions PFD IEC 61508 Probability of failure on demand PFHd IEC 61508 Probability of dan...

Page 26: ...26 Introduction to the manual ACS880 01 HW book Page 26 Monday July 1 2013 4 51 PM...

Page 27: ...pter contains This chapter briefly describes the operation principle and construction of the drive Product overview The ACS880 01 is a drive for controlling asynchronous AC induction motors permanent...

Page 28: ...to alternating current and voltage 4 Brake chopper Conducts the surplus energy from the intermediate DC circuit of the drive to the brake resistor when necessary The chopper operates when the DC link...

Page 29: ...1 The components of the standard IP21 drive are shown below view of frame R5 1 Control panel 2 Front cover 3 Cable entry box 4 Four fastening points at the back of the unit 5 Heatsink 6 Lifting holes...

Page 30: ...ents of the IP55 drive option B056 are shown below view of frame R4 1 Control panel behind the control panel cover 2 Front cover 3 Four fastening points at the back of the unit 4 Heatsink 5 Lifting ho...

Page 31: ...12 drive option B056 are shown below view of frame R6 1 Control panel behind the control panel cover 2 Front cover 3 Four fastening points at the back of the drive 4 Heatsink 5 Lifting holes 6 Hood i...

Page 32: ...ection diagram page 100 and Control unit ZCU 12 connection data page 164 7 See section Control panel page 34 8 du dt common mode or sine filter optional see page 221 Slot 2 L1 L2 L3 PE U T1 V T2 W T3...

Page 33: ...Digital input outputs XDI Digital inputs XSTO Safe torque off connection X12 Connector for safety functions modules optional X13 Control panel PC connection X202 Option slot 1 X203 Option slot 2 X204...

Page 34: ...serial number which allow identification of each unit The type designation label is located on the front cover An example label is shown below No Description 1 Type designation see section Type desig...

Page 35: ...function cable entry box brake chopper in frames R1 to R4 coated boards printed multilingual quick guides and CD containing all manuals Size xxxx Refer to the rating tables page 137 Voltage range 2 2...

Page 36: ...er L516 FEN 21 resolver interface module L517 FEN 01 TTL incremental encoder interface module L518 FEN 11 absolute encoder interface module L525 FAIO 01 analog I O extension module L526 FDIO 01 digita...

Page 37: ...Operation principle and hardware description 37 R713 Polish R714 Turkish CODE DESCRIPTION ACS880 01 HW book Page 37 Monday July 1 2013 4 51 PM...

Page 38: ...38 Operation principle and hardware description ACS880 01 HW book Page 38 Monday July 1 2013 4 51 PM...

Page 39: ...the mechanical installation of the drive Safety WARNING For frame sizes R6 to R9 Use the lifting eyes of the drive when you lift the drive Do not tilt the drive The drive is heavy and its center of g...

Page 40: ...e section Losses cooling data and noise on page 157 The operation conditions of the drive agree with the specifications in section Ambient conditions page 167 The wall is vertical not flammable and st...

Page 41: ...make sure that the drive is of the correct type Item Description Item Description 1 Drive with factory installed options Control cable grounding shelf Romex connectors in IP21 frames R1 to R3 in a pl...

Page 42: ...rd sleeve 5 Lift the drive Frame R5 cable entry box IP21 UL Type 1 This illustration shows the contents of the cable entry box package The package also includes an assembly drawing which shows how to...

Page 43: ...the correct type Item Description Item Description 1 Cable entry box Power and control cable grounding shelves in a plastic bag assembly drawing Note The cable entry box is mounted to the IP55 drive...

Page 44: ...the lifting eyes of the drive Lift the drive with a hoist Frame R6 cable entry box IP21 UL Type 1 This illustration shows the contents of the cable entry box package The package also includes an assem...

Page 45: ...ype 1 This illustration shows the contents of the cable entry box package The package also includes an assembly drawing which shows how to install the cable entry box to the drive module frame 3aua000...

Page 46: ...1 UL Type 1 This illustration shows the contents of the cable entry box package There is also an assembly drawing which shows how to install the cable entry box to the drive module frame 3aua000011217...

Page 47: ...ype 1 This illustration shows the contents of the cable entry box package The package also includes an assembly drawing which shows how to install the cable entry box to the drive module frame 3aua000...

Page 48: ...and on the manuals CD Frames R1 to R4 1 See the dimensions in chapter Dimension drawings Mark the locations for the four mounting holes 2 Drill the mounting holes 3 Start the screws or bolts into the...

Page 49: ...ion dampers on page 50 2 Put the hood onto the upper screws 3 Tighten the upper screws in the wall securely 4 Tighten the lower screws in the wall securely Note Do not open or remove the cable entry b...

Page 50: ...Remove the front cover 5 For IP21 units Attach the cable entry box to the drive frame For instructions see the assembly drawing in the cable entry box A view of frame R5 is shown below 6 Position the...

Page 51: ...Mechanical installation 51 6 1 2 3 Screw size R5 M5 R6 M8 R7 M8 R8 M8 R9 M8 3 200 mm 300 mm 7 87 11 81 4 5 7 ACS880 01 HW book Page 51 Monday July 1 2013 4 51 PM...

Page 52: ...52 Mechanical installation Cabinet installation See ACS880 01 cabinet installation supplement 3AUA0000145446 English ACS880 01 HW book Page 52 Monday July 1 2013 4 51 PM...

Page 53: ...ording 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 recommendati...

Page 54: ...synchronous motor or AC induction servomotor with the drive Several induction motors can be connected to the drive at a time Select the motor size and drive type from to the rating tables in chapter...

Page 55: ...and high switching frequencies can generate current pulses that flow through the motor bearings This can gradually erode the bearing races and rolling elements Optional du dt filters protect motor ins...

Page 56: ...du dt N or Reinforced N 600 V UN 690 V cable length 150 m Reinforced du dt du dt N 600 V UN 690 V cable length 150 m Reinforced N Form wound HX_ and AM_ 380 V UN 690 V Standard n a N CMF Old form wou...

Page 57: ...rosecond rise time N CMF If the intermediate DC circuit voltage of the drive is increased from the nominal level by resistor braking check with the motor manufacturer if additional output filters are...

Page 58: ...e by up to 20 percent Consider this voltage increase when specifying the motor insulation requirements if the motor will be braking a large part of its operation time Example Motor insulation requirem...

Page 59: ...wound motor series for example M3AA M3AP and M3BP Nominal mains voltage AC line voltage Requirement for Motor insulation system ABB du dt and common mode filters insulated N end motor bearings PN 100...

Page 60: ...p or frame size NEMA 500 134 hp PN 469 hp or NEMA 500 frame size NEMA 580 UN 420 V Standard LL 1300 V N or CMF N CMF 420 V UN 500 V Standard LL 1300 V du dt N or CMF du dt N CMF or Reinforced LL 1600...

Page 61: ...ble length proceed as follows Peak line to line voltage Read the relative LL UN value from the appropriate diagram below and multiply it by the nominal supply voltage UN Voltage rise time Read the rel...

Page 62: ...ve peak line to line voltage du dt UN Relative du dt value Note LL and du dt values are approximately 20 higher with resistor braking LL UN l m du dt UN 1 s 1 0 2 0 5 0 4 0 3 0 1 5 2 5 3 5 4 5 100 200...

Page 63: ...conductors of the cable should be at least 1 kV Use symmetrical shielded motor cable see page 66 for drive frame size R5 and larger or motors larger than 30 kW 40 hp A four conductor system can be us...

Page 64: ...type Al cable type mm2 mm2 AWG kcmil AWG kcmil UN 208 240 V 04A6 2 R1 3 1 5 14 06A6 2 R1 3 1 5 14 07A5 2 R1 3 1 5 14 10A6 2 R1 3 1 5 14 16A8 2 R2 3 6 10 24A3 2 R2 3 6 10 031A 2 R3 3 10 8 046A 2 R4 3...

Page 65: ...R1 3 1 5 14 04A8 5 R1 3 1 5 14 05A2 5 R1 3 1 5 14 07A6 5 R1 3 1 5 14 11A0 5 R1 3 1 5 14 014A 5 R2 3 6 10 021A 5 R2 3 6 10 027A 5 R3 3 10 8 034A 5 R3 3 10 8 040A 5 R4 3 16 3 25 6 052A 5 R4 3 25 3 25 4...

Page 66: ...cepted cable sizes of the drive 3 The biggest cable size accepted by the connection terminals of frame R8 is 2 3 150 Biggest possible cable size is 3x240 or 400 MCM if the terminal type is changed and...

Page 67: ...tor and a shield The PE conductor must meet the requirements of IEC 61439 1 A four conductor system three phase conductors and a protective conductor on a cable tray is not allowed for motor cabling i...

Page 68: ...rmor cable with symmetrical grounds or shielded power cable for the motor cables if metallic conduit is not used For the North American market 600 V AC cable is accepted for up to 500 V AC 1000 V AC c...

Page 69: ...ploy one individually shielded pair for each signal Do not use common return for different analog signals A double shielded cable figure a below is the best alternative for low voltage digital signals...

Page 70: ...rallel runs of motor cables with other cables in order to decrease electromagnetic interference caused by the rapid changes in the drive output voltage Where control cables must cross power cables ens...

Page 71: ...ween the drive and the motor European Union Install the equipment in a metal enclosure with 360 degree grounding for the shields of both the incoming and outgoing cable or connect the shields of the c...

Page 72: ...ected 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 t...

Page 73: ...on page 197 Note Pressing the stop key on the control panel of the drive does not generate an emergency stop of the motor or separate the drive from dangerous potential Implementing the Safe torque of...

Page 74: ...ters to the motor cables between the drive and the motor They are not meant to be used with AC drives and can cause permanent damage to the drive or themselves If there are power factor compensation c...

Page 75: ...r control operates extremely fast much faster than it takes for the contactor to open its contacts When the contactor starts opening while the drive controls the motor the DTC control will try to main...

Page 76: ...ive main contactor on off control Q4 Bypass circuit breaker S40 Motor power supply selection drive or direct on line K1 Drive main contactor S41 Start when motor is connected direct on line K4 Bypass...

Page 77: ...1 4 Start the drive and the motor with the drive control panel drive in local control mode or with the external start signal drive in remote control mode Protecting the contacts of relay outputs Induc...

Page 78: ...78 Planning the electrical installation 1 Relay outputs 2 Varistor 3 RC filter 4 diode 230 V AC 230 V AC 24 V DC 1 2 3 4 ACS880 01 HW book Page 78 Monday July 1 2013 4 51 PM...

Page 79: ...e digital inputs of the drive can be implemented in three alternate ways 1 There is double or reinforced insulation between the thermistor and live parts of the motor 2 Circuits connected to all digit...

Page 80: ...80 Planning the electrical installation ACS880 01 HW book Page 80 Monday July 1 2013 4 51 PM...

Page 81: ...y or death Checking the insulation of the assembly Drive Do not make any voltage tolerance or insulation resistance tests on any part of the drive as testing can damage the drive Every drive has been...

Page 82: ...s instructions Note Moisture inside the motor casing will reduce the insulation resistance If moisture is suspected dry the motor and repeat the measurement Brake resistor assembly Check the insulatio...

Page 83: ...h EMC AC and EMC DC on the skeleton See EMC filter disconnecting instructions for ACS880 01 drives with filters E200 and E202 3AUA0000125152 English For frame R4 contact ABB WARNING If a drive with EM...

Page 84: ...ounding cable if the shield does not meet the requirements of IEC 61439 1 see page 63 and there is no symmetrically constructed grounding conductor in the cable see page 68 7 du dt filter or sine filt...

Page 85: ...ector onto the stripped part of the cable IP55 units Tighten the clamps onto the stripped part of the cables 8 Connect the twisted shields of the power cables to the grounding terminals 9 Connect the...

Page 86: ...86 Electrical installation 2 1 1 3 5 10 4 IP21 IP55 1 ACS880 01 HW book Page 86 Monday July 1 2013 4 51 PM...

Page 87: ...llation 87 T3 W T2 V T1 U UDC R R L3 L2 L1 L1 L2 L3 T1 U T2 V T3 W R R UDC UDC N m N m R1 0 6 1 8 R2 0 6 1 8 R3 1 7 1 8 7 8 8 9 10 10 6b PE PE 9 8 6a PE PE 6b 8 8 ACS880 01 HW book Page 87 Monday July...

Page 88: ...oles into the rubber grommets Slide the grommets onto the cables Slide the cables through the holes of the bottom plate and attach the grommets to the holes 7 Prepare the ends of the input power and m...

Page 89: ...nd R terminals and tighten to the torque given in the figure 13 Reinstall the shroud on the power terminals 14 Secure the cables outside the unit mechanically Install the rubber grommets to the unused...

Page 90: ...90 Electrical installation 2 1b 1a 4b 4 4a 3 3 IP55 IP21 1 ACS880 01 HW book Page 90 Monday July 1 2013 4 51 PM...

Page 91: ...Electrical installation 91 6 6 7 5 PE PE 7 6 ACS880 01 HW book Page 91 Monday July 1 2013 4 51 PM...

Page 92: ...92 Electrical installation 12 13 9 L1 L2 L3 T1 U T2 V T3 W N m R R UDC UDC N m N m R4 3 3 3 3 2 9 R5 15 15 2 9 8 9 10 9 10 11 ACS880 01 HW book Page 92 Monday July 1 2013 4 51 PM...

Page 93: ...hrough the holes of the bottom plate and attach the grommets to the holes b 9 Tighten the clamp onto the stripped part of the cable 10 Fasten the twisted shields of the cables under the grounding clam...

Page 94: ...94 Electrical installation 1a 2 1b 4 5a 3 2 5b 3 4 IP55 IP21 ACS880 01 HW book Page 94 Monday July 1 2013 4 51 PM...

Page 95: ...Electrical installation 95 6 8a 7 PE PE 7 R8 R9 ACS880 01 HW book Page 95 Monday July 1 2013 4 51 PM...

Page 96: ...96 Electrical installation 8b R8 R9 ACS880 01 HW book Page 96 Monday July 1 2013 4 51 PM...

Page 97: ...R UDC UDC T Wire screw T Terminal nut T Wire screw T Terminal nut T M N m M N m M N m M N m N m R6 M10 30 M8 24 M8 20 M8 20 9 8 R7 M10 40 30 M8 24 M10 30 M10 30 9 8 R8 M10 40 M10 24 M10 40 M8 24 9 8...

Page 98: ...98 Electrical installation 16 13 R8 R9 ACS880 01 HW book Page 98 Monday July 1 2013 4 51 PM...

Page 99: ...n DC configurations of a number of drives allowing regenerative energy from one drive to be utilized by the other drives in motoring mode Contact your local ABB representative for further instructions...

Page 100: ...30 V DC 2 A 2 COM 3 NO 1 NC Running 250 V AC 30 V DC 2 A 2 COM 3 NO 1 NC Faulted 1 250 V AC 30 V DC 2 A 2 COM 3 NO XD24 Digital interlock 1 DIIL By default not in use 2 24VD 24 V DC 200 mA 3 3 DICOM D...

Page 101: ...Jumpers and switches DI4 Ramp times according to 0 Parameters 23 12 and 23 13 1 Parameters 23 14 and 23 15 Jumper Switch Description Positions J1 AI1 Determines whether analog input AI1 is used as a c...

Page 102: ...Do not connect both ends of the cable shields directly to ground If a capacitor cannot be used at one end leave that end of the shield unconnected WARNING As the inputs pictured above are not insulat...

Page 103: ...air cable 100 ohm for example PROFIBUS compatible cable for the wiring For best immunity high quality cable is recommended Keep the cable as short as possible the maximum length of the link is 50 mete...

Page 104: ...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 See page 197 Safety functions X12 See sec...

Page 105: ...tinuous as close to the terminals of the control unit as possible Secure the cables mechanically at the clamps below the control unit Frames R1 to R3 Ground also the pair cable shields and grounding w...

Page 106: ...106 Electrical installation 6 5 7 7 1 5 N m 0 5 N m 3 3 1 5 N m ACS880 01 HW book Page 106 Monday July 1 2013 4 51 PM...

Page 107: ...USB Type Mini B as follows 1 Lift the USB connector cover from bottom upwards 2 Insert the USB cable Mini B plug in the control panel USB connector 3 Insert the USB cable A plug in the USB connector...

Page 108: ...45 connector 3 Connect the other end of the cable to the left hand side RJ 45 connector in the control panel housing of the first drive 4 Connect another cable to the right hand side RJ 45 connector i...

Page 109: ...tional modules as follows WARNING Follow the safety instructions page 14 Ignoring the instructions can cause physical injury or death or damage to the equipment 1 Disconnect the drive from the power l...

Page 110: ...fieldbus adapter and pulse encoder interface modules See the appropriate optional module manual for specific installation and wiring instructions See page 106 for the routing of the cables 3 4 5 ACS88...

Page 111: ...mounting platform upwards to gain access to the optional module slots 4 Insert the module carefully into its position on the control unit 5 Attach the module with four screws Note The grounding screw...

Page 112: ...112 Electrical installation 3 5 5a 5 5 6 X12 ACS880 01 HW book Page 112 Monday July 1 2013 4 51 PM...

Page 113: ...ws Note Correct installation of the grounding screw a is essential for fulfilling the EMC requirements and for proper operation of the module 5 Tighten the grounding screw of the electronics 6 Connect...

Page 114: ...114 Electrical installation X12 6 1 4 4a 4 4 5 ACS880 01 HW book Page 114 Monday July 1 2013 4 51 PM...

Page 115: ...can cause injury or death Open the main disconnector of the drive and lock it to open position Measure to ensure that the drive is not powered Check that The ambient operating conditions meet the spe...

Page 116: ...terminals have been tightened pull conductors to check The brake resistor cable if present has been connected to appropriate terminals and the terminals have been tightened pull conductors to check Th...

Page 117: ...t up instructions given in Quick start up guide for ACS880 primary control program or in the firmware manual 2 Validate the Safe torque off function according to the instructions given in chapter Safe...

Page 118: ...118 Start up ACS880 01 HW book Page 118 Monday July 1 2013 4 51 PM...

Page 119: ...ages See the firmware manual for the descriptions causes and remedies of the drive control program warning and fault messages Where LED Color When the LED is lit Control panel mounting platform POWER...

Page 120: ...120 Fault tracing ACS880 01 HW book Page 120 Monday July 1 2013 4 51 PM...

Page 121: ...d by ABB The recommended maintenance intervals and component replacements are based on specified operational and environmental conditions ABB recommends annual drive inspections to ensure the highest...

Page 122: ...apacitor reforming P P P P P P P P P P P P P P P P P P P P P Recommended annual cleanings by user Clean the IP22 Ul Type 1 and IP42 UL Type 1 Filtered inlet meshes on the cabinet door Clean the heatsi...

Page 123: ...nd ensure by measuring that there is no voltage 2 Remove the cooling fan s See section Fans below 3 Blow clean compressed air not humid from bottom to top and simultaneously use a vacuum cleaner at th...

Page 124: ...ath or damage to the equipment 1 Disconnect the drive from the power line Lock the main disconnecting device and ensure by measuring that there is no voltage 2 Release the retaining clip by pushing wi...

Page 125: ...r line Lock the main disconnecting device and ensure by measuring that there is no voltage 2 Remove the front cover by undoing the mounting screws at the sides 3 Unplug the fan power supply wires 4 Li...

Page 126: ...ipment 1 Disconnect the drive from the power line Lock the main disconnecting device and ensure by measuring that there is no voltage 2 Lift the fan mounting plate up from the front edge 3 Unplug the...

Page 127: ...death or damage to the equipment 1 Disconnect the drive from the power line Lock the main disconnecting device and ensure by measuring that there is no voltage 2 Remove the front cover 3 Unplug the f...

Page 128: ...power line Lock the main disconnecting device and ensure by measuring that there is no voltage 2 Undo the mounting screws of the fan mounting plate view from bottom below 3 Pull the fan mounting plate...

Page 129: ...ice and ensure by measuring that there is no voltage 2 Remove the lower front cover see page 93 3 Unplug the control panel power supply wires from the control unit terminal X13 and the auxiliary cooli...

Page 130: ...h or damage to the equipment 1 Disconnect the drive from the power line Lock the main disconnecting device and ensure by measuring that there is no voltage 2 Remove the IP55 front cover 3 Remove the l...

Page 131: ...Maintenance 131 3 4 5 3 ACS880 01 HW book Page 131 Monday July 1 2013 4 51 PM...

Page 132: ...Lock the main disconnecting device and ensure by measuring that there is no voltage 2 Undo the two mounting screws of the fan mounting plate view from drive bottom below 3 Turn the mounting plate down...

Page 133: ...t 1 Disconnect the drive from the power line Lock the main disconnecting device and ensure by measuring that there is no voltage 2 Remove the front covers See section Connection procedure for frames R...

Page 134: ...tic capacitors Their lifespan depends on the operating time of the drive loading and ambient temperature Capacitor life can be prolonged by lowering the ambient temperature In frames R1 to R3 the capa...

Page 135: ...glish Memory unit When a drive is replaced the parameter settings can be retained by transferring the memory unit from the defective drive to the new drive The memory unit is located on the control un...

Page 136: ...ery Dispose the old battery according to local disposal rules or applicable laws Replacing safety functions modules FSO 11 option Q973 Do not repair safety functions modules Replace a faulty module wi...

Page 137: ...urrent Output ratings Nominal use Light overload use Heavy duty use I1N Imax IN PN ILd PLd IHd PHd A A A kW A kW A kW UN 208 240 V 04A6 2 R1 4 6 6 3 4 6 0 75 4 4 0 75 3 7 0 55 06A6 2 R1 6 6 7 8 6 6 1...

Page 138: ...5 11 24 11 17 7 5 032A 3 R3 32 42 32 15 30 15 25 11 038A 3 R3 38 54 38 18 5 36 18 5 32 15 0 045A 3 R4 45 64 45 22 43 22 38 19 061A 3 R4 61 76 61 30 58 30 45 22 072A 3 R5 72 104 72 37 68 37 61 30 087A...

Page 139: ...5 R4 40 64 40 22 38 22 34 19 052A 5 R4 52 76 52 30 49 30 40 22 065A 5 R5 65 104 65 37 62 37 52 30 077A 5 R5 77 122 77 45 73 45 65 37 096A 5 R6 96 148 96 55 91 55 77 45 124A 5 R6 124 178 124 75 118 75...

Page 140: ...37 061A 7 R6 61 104 61 55 58 55 49 45 084A 7 R6 84 124 84 75 80 75 61 55 098A 7 R7 98 168 98 90 93 90 84 75 119A 7 R7 119 198 119 110 113 110 98 90 142A 7 R8 142 250 142 132 135 132 119 110 174A 7 R8...

Page 141: ...1 2 2 3 0 7 5 1 5 2 0 16A8 2 R2 16 8 18 0 16 0 4 0 5 0 10 6 2 2 3 0 24A3 2 R2 24 3 28 6 23 1 5 5 7 5 16 8 4 0 5 0 031A 2 R3 31 0 41 29 3 7 5 10 24 3 5 5 7 5 046A 2 R4 46 64 44 11 15 38 7 5 10 061A 2 R...

Page 142: ...25 052A 5 R4 52 76 52 30 40 40 22 30 065A 5 R5 65 104 65 37 50 52 30 40 077A 5 R5 77 122 77 45 60 65 37 50 096A 5 R6 96 148 96 55 75 77 45 60 124A 5 R6 124 178 124 75 100 96 55 75 156A 5 R7 156 247 1...

Page 143: ...in light overload use Imax Maximum output current Available for 10 seconds at start then as long as allowed by drive temperature IHd Continuous rms output current allowing 50 overload for 1 minute eve...

Page 144: ...k IP55 UL Type 12 drive type 240A 5 In the temperature range 40 50 C 104 122 F the rated output current is derated by 1 for every added 1 C 1 8 F In the temperature range 50 55 C 122 131 F the rated o...

Page 145: ...protection on page 71 Note 2 Fuses with higher current rating than the recommended ones must not be used Smaller fuses can be used Note 3 Fuses from other manufacturers can be used if they meet the r...

Page 146: ...ssmann 170M1566 000 061A 3 380 61 100 4650 690 Bussmann 170M1567 000 072A 3 480 72 125 8500 690 Bussmann 170M1568 000 087A 3 480 87 125 8500 690 Bussmann 170M1568 000 105A 3 700 105 160 16000 690 Buss...

Page 147: ...30 275000 690 Bussmann 170M5812 2 UN 525 690 V 07A3 7 40 7 3 16 48 690 Bussmann 170M1559 000 09A8 7 53 9 8 20 78 690 Bussmann 170M1560 000 14A2 7 94 14 2 32 270 690 Bussmann 170M1562 000 018A 7 120 18...

Page 148: ...7A 2 1300 87 125 100000 500 ABB OFAF00H125 00 115A 2 1700 115 160 170000 500 ABB OFAF00H160 00 145A 2 2300 145 200 300000 500 ABB OFAF0H200 0 UN 380 415 V 02A4 3 17 2 4 4 53 500 ABB OFAF000H4 000 03A3...

Page 149: ...500 ABB OFAF000H100 000 077A 5 1000 77 100 63600 500 ABB OFAF000H100 000 096A 5 1300 96 125 103000 500 ABB OFAF00H125 00 124A 5 1700 124 160 185000 500 ABB OFAF00H160 00 UN 525 690 V 07A3 7 115 7 3 1...

Page 150: ...1 5 3 3 4 3 1 1 1 2 10A6 2 3 1 5 3 3 4 3 1 5 1 8 16A8 2 3 6 5 5 5 8 1 8 1 8 24A3 2 3 6 9 7 11 3 3 3 5 031A 2 3 10 11 12 4 4 4 6 046A 2 3 16 3 35 14 15 7 7 8 2 061A 2 3 25 3 35 22 24 8 3 8 6 075A 2 3...

Page 151: ...5 3 35 3 70 60 61 63 29 29 30 096A 5 3 50 3 70 78 80 83 42 43 45 124A 5 3 95 3 120 103 105 108 57 59 61 UN 525 690 V 07A3 7 3 1 5 9 5 9 7 10 4 3 3 3 3 3 5 09A8 7 3 1 5 12 12 14 4 4 4 5 4 7 14A2 7 3 2...

Page 152: ...o line voltage V Rc cable resistance ohm Zk zk UN 2 SN transformer impedance ohm zk transformer impedance UN transformer rated voltage V SN nominal apparent power of the transformer kVA Xc cable react...

Page 153: ...R6 and below 0 1 seconds for units of frame sizes R7 to R9 Follow local regulations Note 1 See also Implementing thermal overload and short circuit protection on page 71 Note 2 Fuses with higher curre...

Page 154: ...JJS 300 T 274A 2 274 400 600 Bussmann JJS 400 T UN 440 480 V 02A1 5 2 1 3 600 Bussmann JJS 3 T 03A0 5 3 0 6 600 Bussmann JJS 6 T 03A4 5 3 4 6 600 Bussmann JJS 6 T 04A8 5 4 8 10 600 Bussmann JJS 10 T 0...

Page 155: ...ussmann JJS 400 T 361A 5 361 500 600 Bussmann JJS 500 T 414A 5 414 600 600 Bussmann JJS 600 T Drive type ACS880 01 Input current Fuse one fuse per phase A A V Manufacturer Type UL class ACS880 01 HW b...

Page 156: ...55 226 6 15 94 14 57 6 10 8 89 13 R2 405 370 155 249 8 15 94 14 57 6 10 9 80 18 R3 471 420 172 261 10 18 54 16 54 6 77 10 28 22 R4 576 490 203 274 18 5 22 70 19 30 7 99 10 80 41 R5 730 596 203 274 23...

Page 157: ...256 940 67 170A 2 R7 450 265 1260 67 206A 2 R7 450 265 1500 67 274A 2 R8 550 324 2100 65 UN 380 415 V 02A4 3 R1 44 26 30 46 03A3 3 R1 44 26 40 46 04A0 3 R1 44 26 52 46 05A6 3 R1 44 26 73 46 07A2 3 R1...

Page 158: ...0 165 1120 62 096A 5 R6 435 256 1295 67 124A 5 R6 435 256 1440 67 156A 5 R7 450 265 1940 67 180A 5 R7 450 265 2310 67 240A 5 R8 550 324 3300 65 260A 5 R8 550 324 3900 65 302A 5 R9 1150 677 4200 68 361...

Page 159: ...67 119A 7 R7 450 265 2310 67 142A 7 R8 550 324 3300 65 174A 7 R8 550 324 3900 65 210A 7 R9 1150 677 4200 68 271A 7 R9 1150 677 4800 68 Drive type ACS880 01 Frame Air flow Heat dissipation Noise m3 h f...

Page 160: ...2 N m R1 1 17 0 75 6 0 6 8 25 1 8 R2 1 17 0 75 6 0 6 8 25 1 8 R3 1 21 0 5 16 1 7 10 25 1 8 R4 1 24 0 5 35 3 3 18 25 2 9 R5 1 32 6 70 M8 15 18 35 2 9 R6 1 45 25 150 M10 30 30 185 9 8 R7 1 54 95 240 25...

Page 161: ...18 10 0 4 0 31 4 1 3 R3 1 0 83 20 6 1 3 0 39 4 1 3 R4 1 0 94 20 2 2 4 0 70 4 2 1 R5 1 1 26 4 1 0 M8 11 0 0 70 2 2 1 R6 1 1 77 3 300 MCM M10 22 1 1 18 350 MCM 7 2 R7 1 2 13 4 0 400 MCM 3 300 MCM M10 29...

Page 162: ...1 Ilsco CCL 4 38 Ilsco MT 25 1 2 Thomas Betts 54143TB 54142TB Thomas Betts TBM4S TBM4S 1 Burndy YA2C L4BOX Burndy MY29 3 2 Ilsco CRC 2 Ilsco IDT 12 1 Ilsco CCL 2 38 Ilsco MT 25 1 1 Thomas Betts 54148...

Page 163: ...e 17 s Imbalance Max 3 of nominal phase to phase input voltage Fundamental power factor cos phi1 0 98 at nominal load Motor connection data Motor types Asynchronous AC induction motors permanent magne...

Page 164: ...n alternatively be used as an input for PTC sensors 0 4 kohm 1 1 5 kohm Imax 15 mA for DI6 5 mA Start interlock input DIIL XD24 1 Connector pitch 5 mm wire size 2 5 mm2 24 V logic levels 0 5 V 1 15 V...

Page 165: ...s AO1 and AO2 XAO Connector pitch 5 mm wire size 2 5 mm2 0 20 mA Rload 500 ohm Frequency range 0 300 Hz Resolution 11 bit sign bit Inaccuracy 2 of full scale range Drive to drive link XD2D Connector p...

Page 166: ...4 DIIL 1 24VD 2 DICOM 3 24VD 4 DIOGND 5 XDIO DIO1 1 DIO2 2 XDI DI1 1 DI2 2 DI3 3 DI4 4 DI5 5 DI6 6 XSTO OUT1 1 SGND 2 IN1 3 IN2 4 J6 Ground Common mode voltage between channels 30 V Switch J6 settings...

Page 167: ...ft above sea level 2 0 to 2000 m 6561 ft above sea level Above 1000 m 3281 ft see page 145 1 for neutral grounded TN and TT systems and non corner grounded IT systems 2 for corner grounded TN TT and I...

Page 168: ...coated steel sheet 1 5 to 2 5 mm thickness of coating 100 micrometers color NCS 1502 Y Package Plywood and cardboard Foam cushions PP E bands PP Disposal The main parts of the drive can be recycled to...

Page 169: ...of machinery Electrical equipment of machines Part 1 General requirements Provisions for compliance The final assembler of the machine is responsible for installing emergency stop device supply discon...

Page 170: ...electronic product which is covered by the European Low Voltage Directive However the drive includes the Safe torque off function and can be equipped with other safety functions for machinery which as...

Page 171: ...Technical data 171 Declaration of Conformity ACS880 01 HW book Page 171 Monday July 1 2013 4 51 PM...

Page 172: ...172 Technical data ACS880 01 HW book Page 172 Monday July 1 2013 4 51 PM...

Page 173: ...than 1000 V and intended for use in the second environment and not intended for use in the first environment Drive of category C4 drive of rated voltage equal to or above 1000 V or rated current equa...

Page 174: ...of the standard can be met as follows 1 It is ensured that no excessive emission is propagated to neighboring low voltage networks In some cases the inherent suppression in transformers and cables is...

Page 175: ...current The current is derated for 40 to 55 C 104 to 131 F The drive is suitable for use in a circuit capable of delivering not more than 100 000 rms symmetrical amperes 600 V maximum The ampere rati...

Page 176: ...pending for drives of voltage ranges 204 240 V and 525 690 V For fulfilling the requirements of the standard see section Compliance with the EN 61800 3 2004 on page 173 GOST R certificate of conformi...

Page 177: ...Dimension drawings 177 12 Dimension drawings What this chapter contains This chapter contains dimension drawings of the drive ACS880 01 HW book Page 177 Monday July 1 2013 4 51 PM...

Page 178: ...178 Dimension drawings Frame R1 IP21 UL Type 1 3AUA0000097621 ACS880 01 HW book Page 178 Monday July 1 2013 4 51 PM...

Page 179: ...Dimension drawings 179 Frame R2 IP21 UL Type 1 3AUA0000097691 ACS880 01 HW book Page 179 Monday July 1 2013 4 51 PM...

Page 180: ...180 Dimension drawings Frame R3 IP21 UL Type 1 3AUA0000097847 ACS880 01 HW book Page 180 Monday July 1 2013 4 51 PM...

Page 181: ...98 3 86 475 18 70 SUGGESTED MOUNTING HOLES 505 19 88 490 19 291 WITHOUT GLAND BOX 7 26 203 7 99 13 51 22 85 8 32 18 72 7 26 15 57 22 85 7 28 PLATE HOLE 44 1 73 3pcs GROMMET UP TO 24 0 94 CABLE DIAMETE...

Page 182: ...MOUNTING HOLES 612 24 07 596 23 46 WITHOUT GLAND BOX 7 26 274 10 77 65 2 55 74 2 90 48 1 88 730 28 73 203 7 99 124 4 86 7 26 8 32 22 85 A B PLATE HOLE 51 2 01 3pcs GROMMET UP TO 32 1 26 CABLE DIAMETE...

Page 183: ...Dimension drawings 183 Frame R6 IP21 UL Type 1 3AUA0000098321 ACS880 01 HW book Page 183 Monday July 1 2013 4 51 PM...

Page 184: ...184 Dimension drawings Frame R7 IP21 UL Type 1 3AUA0000073149 ACS880 01 HW book Page 184 Monday July 1 2013 4 51 PM...

Page 185: ...Dimension drawings 185 Frame R8 IP21 UL Type 1 3AUA0000073150 ACS880 01 HW book Page 185 Monday July 1 2013 4 51 PM...

Page 186: ...186 Dimension drawings Frame R9 IP21 UL Type 1 3AUA0000073151 ACS880 01 HW book Page 186 Monday July 1 2013 4 51 PM...

Page 187: ...Dimension drawings 187 Frame R1 IP55 UL Type 12 3AUA0000097621 ACS880 01 HW book Page 187 Monday July 1 2013 4 51 PM...

Page 188: ...188 Dimension drawings Frame R2 IP55 UL Type 12 3AUA0000097691 ACS880 01 HW book Page 188 Monday July 1 2013 4 51 PM...

Page 189: ...Dimension drawings 189 Frame R3 IP55 UL Type 12 3AUA0000097847 ACS880 01 HW book Page 189 Monday July 1 2013 4 51 PM...

Page 190: ...53 160 6 30 SUGGESTED MOUNTING HOLES 98 3 86 475 18 70 SUGGESTED MOUNTING HOLES 505 19 88 490 19 291 7 28 22 85 22 85 8 32 18 72 PLATE HOLE 44 1 73 3pcs GROMMET UP TO 24 0 94 CABLE DIAMETER PLATE HOL...

Page 191: ...NTING HOLES 581 22 87 SUGGESTED MOUNTING HOLES 612 24 07 7 26 596 23 46 WITHOUT GLAND BOX 344 13 53 54 2 11 96 3 78 730 28 73 29 1 13 165 6 51 A B PLATE HOLE 29 1 12 GROMMET UP TO 22 0 87 CABLE DIAMET...

Page 192: ...192 Dimension drawings Frame R6 IP55 UL Type 12 3AUA0000098321 ACS880 01 HW book Page 192 Monday July 1 2013 4 51 PM...

Page 193: ...Dimension drawings 193 Frame R7 IP55 UL Type 12 3AUA0000073149 ACS880 01 HW book Page 193 Monday July 1 2013 4 51 PM...

Page 194: ...194 Dimension drawings Frame R8 IP55 UL Type 12 3AUA0000073150 ACS880 01 HW book Page 194 Monday July 1 2013 4 51 PM...

Page 195: ...Dimension drawings 195 Frame R9 IP55 UL Type 12 3AUA0000073151 ACS880 01 HW book Page 195 Monday July 1 2013 4 51 PM...

Page 196: ...196 Dimension drawings ACS880 01 HW book Page 196 Monday July 1 2013 4 51 PM...

Page 197: ...rk on non electrical parts of the machinery without switching off the power supply to the drive When activated the Safe torque off function disables the control voltage of the power semiconductors of...

Page 198: ...ernal 24 V DC power supply is used page 202 For information on the specifications of the STO input see section Control unit ZCU 12 connection data on page 164 Activation switch In the wiring diagrams...

Page 199: ...witch K and drive control unit 60 m 200 ft between multiple drives 60 m 200 ft between external power supply and first drive Note that the voltage at the INx terminals of each drive must be at least 1...

Page 200: ...200 Safe Torque off function Single drive internal power supply 24 V OUT1 SGND IN1 IN2 ACS880 01 ZCU T1 U T2 V T3 W UDC UDC A Control logic K ACS880 01 HW book Page 200 Monday July 1 2013 4 51 PM...

Page 201: ...off function 201 Multiple drives internal power supply OUT1 SGND IN1 IN2 ACS880 01 ZCU OUT1 SGND IN1 IN2 ACS880 01 ZCU K 24 V OUT1 SGND IN1 IN2 ACS880 01 ZCU ACS880 01 HW book Page 201 Monday July 1 2...

Page 202: ...off function Multiple drives external power supply 24 V OUT1 ACS880 01 ZCU OUT1 SGND IN1 IN2 ACS880 01 ZCU OUT1 SGND IN1 IN2 ACS880 01 ZCU 24 V DC K SGND IN1 IN2 ACS880 01 HW book Page 202 Monday July...

Page 203: ...the machine must validate the function by performing an acceptance test The acceptance test must be performed at initial start up of the safety function after any changes related to the safety functi...

Page 204: ...rates as follows Open the STO circuit The drive generates an indication if one is defined for stopped state in parameter 31 22 see the firmware manual Give a start command to verify that the STO funct...

Page 205: ...agnet or synchronous reluctance SynRM motors only In case of a multiple IGBT power semiconductor failure the drive system can produce an alignment torque which maximally rotates the motor shaft by 180...

Page 206: ...rformed and the drive trips on an STO hardware failure fault An attempt to use the STO in a non redundant manner for example activating only one channel will trigger the same reaction See the drive fi...

Page 207: ...t circuit on printed circuit board has been made EN 13849 2 table D 5 The analysis is based on an assumption that one failure occurs at one time No accumulated failures have been analyzed R9 3 3 84E 0...

Page 208: ...s typical 5 ms maximum Fault detection time Channels in different states for longer than 200 ms Fault reaction time Fault detection time 10 ms STO fault indication parameter 31 22 delay 500 ms STO war...

Page 209: ...Safe Torque off function 209 Certificate ACS880 01 HW book Page 209 Monday July 1 2013 4 51 PM...

Page 210: ...210 Safe Torque off function ACS880 01 HW book Page 210 Monday July 1 2013 4 51 PM...

Page 211: ...opper connects the brake resistor to the intermediate DC circuit whenever the voltage in the circuit exceeds the limit defined by the control program Energy consumption by the resistor losses lowers t...

Page 212: ...ur resistor assembly in which two standard resistors are connected in parallel two in series The ER value of the four resistor assembly is four times the value specified for the standard resistor Sele...

Page 213: ...mum 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 resistor...

Page 214: ...ve in a fault situation An example wiring diagram is shown below ABB resistors are equipped with a thermal switch 1 inside the resistor assembly as standard The switch indicates overtemperature and ov...

Page 215: ...sulation of the assembly Follow the instructions given under Brake resistor assembly on page 82 Connection diagram See section Connection diagram on page 84 Connection procedure Connect the resistor c...

Page 216: ...application For frames R5 to R9 Set parameter 43 07 Brake chopper runtime enable to Other bit and select from parameter 10 01 DI status the digital input where the thermal switch of the brake resistor...

Page 217: ...2 45 2 4 SAFUR200F500 2 7 5400 13 5 ACS880 01 206A 2 55 2 4 SAFUR200F500 2 7 5400 13 5 ACS880 01 274A 2 75 1 8 2 SAFUR125F500 2 7200 18 UN 380 415 V ACS880 01 02A4 3 0 75 210 2 JBR 01 240 44 0 21 ACS...

Page 218: ...5 22 13 SACE15RE13 13 435 2 ACS880 01 052A 5 22 13 SACE15RE13 13 435 2 ACS880 01 065A 5 37 8 SAFUR90F575 8 1800 4 5 ACS880 01 077A 5 45 8 SAFUR90F575 8 1800 4 5 ACS880 01 096A 5 55 5 4 SAFUR80F500 6 2...

Page 219: ...ee section Terminal and lead through data for the power cables on page 160 ACS880 01 035A 7 33 18 SACE15RE22 22 420 2 ACS880 01 042A 7 45 18 SACE15RE22 22 420 2 ACS880 01 049A 7 45 18 SACE15RE22 22 42...

Page 220: ...220 Resistor braking ACS880 01 HW book Page 220 Monday July 1 2013 4 51 PM...

Page 221: ...ecking the compatibility of the motor and drive page 54 A common mode filter kit is available from ABB with order number is 64315811 for the drive The kit includes three wound cores For installation i...

Page 222: ...X 09A4 3 NOCH0016 6X 07A6 5 NOCH0016 6X 026A 7 NOCH0030 6X 12A6 3 NOCH0016 6X 11A0 5 NOCH0016 6X 035A 7 NOCH0070 6X 017A 3 NOCH0016 6X 014A 5 NOCH0016 6X 042A 7 NOCH0070 6X 025A 3 NOCH0030 6X 021A 5 N...

Page 223: ...ning navigate to www abb com drives and select Training courses Providing feedback on ABB Drives manuals Your comments on our manuals are welcome Go to www abb com drives and select Document Library M...

Page 224: ...Contact us www abb com drives www abb com drivespartners 3AUA0000078093 Rev G EN EFFECTIVE 2013 07 01 ACS880 01 HW book Page 224 Monday July 1 2013 4 51 PM...

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