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Resistor braking

Contents of this chapter

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

When is resistor braking necessary?

Resistor braking is necessary for high capacity braking if a regenerative drive cannot
be used.

Operation principle and hardware description

The drive 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 extra
energy increases the DC link voltage. 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

￭

Generic guidelines

This section contains generic brake cable type, length and placing instructions, rules
on how to minimize electromagnetic interference and descriptions and requirements
for protections.

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Resistor braking 191

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Summary of Contents for ACS880-04F-504A-3

Page 1: ... ABB INDUSTRIAL DRIVES ACS880 04F drive modules Hardware manual ...

Page 2: ......

Page 3: ...0 04F drive modules Hardware manual Table of contents 1 Safety instructions 5 Mechanical installation 7 Electrical installation 10 Start up 3AXD50000034664 Rev D EN Original instructions EFFECTIVE 2022 08 31 ...

Page 4: ......

Page 5: ...l 21 Categorization by frame size and option code 22 Quick installation commissioning and operating flowchart 23 Terms and abbreviations 25 Related documents 3 Operation principle and hardware description 27 Contents of this chapter 28 Product overview 29 Layout 29 Standard drive module configuration 31 Drive module without full size output cable connection terminals option 0H371 and IP20 shrouds ...

Page 6: ...tation of liability 57 Selecting the main supply disconnecting device 57 European Union and United Kingdom 58 North America 58 Other regions 58 Selecting the main contactor 58 North America 58 Other regions 58 Examining the compatibility of the motor and drive 59 Protecting the motor insulation and bearings 59 Requirements tables 59 Requirements for ABB motors Pn 100 kW 134 hp 60 Requirements for ...

Page 7: ...ecting the motor and motor cable in short circuits 74 Protecting the motor cables against thermal overload 75 Protecting the motor against thermal overload 75 Protecting the motor against overload without thermal model or temperature sensors 75 Protecting the drive against ground faults 76 Residual current device compatibility 76 Connecting drive modules to a common DC system 76 Implementing a mot...

Page 8: ...mp plate 91 Connecting the external control unit to the drive module 91 Control unit connection cables 92 Routing the control unit cables into the drive module 92 Connections to the drive module 93 Connections to the control unit 94 Connecting the control cables to the terminals of the external control unit 95 Installing the control panel holder back onto the external control unit 96 Connecting a ...

Page 9: ...ment cooling fans 123 Replacing the main cooling fans 124 Replacing the standard drive module 125 Capacitors 125 Reforming the capacitors 125 Control panel 125 Replacing the ZCU 14 control unit battery 126 Replacing the memory unit of ZCU 14 127 Functional safety components 13 Ordering information 129 Contents of this chapter 129 Output du dt filters 129 Sine filters 130 FSO accessories kit 130 Re...

Page 10: ...es for module 150 Ambient conditions 151 Colors 151 Materials 151 Drive 151 Package materials for module products 151 Package materials for options accessories and spare parts 151 Materials of manuals 151 Disposal 152 Applicable standards 152 Markings 153 EMC compliance IEC EN 61800 3 153 Definitions 154 Category C3 154 Category C4 155 Compliance with the European Machinery Directive 156 UL checkl...

Page 11: ...79 Validation test procedure 181 Use 182 Maintenance 182 Competence 183 Perfect proof test procedure 183 Simplified proof test procedure 184 Fault tracing 185 Safety data 187 Terms and abbreviations 188 TÜV certificate 189 Declarations of conformity 18 Resistor braking 191 Contents of this chapter 191 When is resistor braking necessary 191 Operation principle and hardware description 191 Planning ...

Page 12: ... 198 Terminals and cable entry data 19 Filters 199 Contents of this chapter 199 du dt filters 199 When is a du dt filter necessary 199 Selection table 200 Ordering codes 200 Description installation and technical data of the FOCH filters 200 Sine filters 200 When is a sine filter necessary 200 Selection table 200 Ordering codes 200 Derating 200 Description installation and technical data of the si...

Page 13: ...you how to prevent the danger Notes draw attention to a particular condition or fact or give information on a subject The manual uses these warning symbols WARNING Electricity warning tells about hazards from electricity which can cause injury or death or damage to the equipment WARNING General warning tells about conditions other than those caused by electricity which can cause injury or death or...

Page 14: ... points See the dimension drawings 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 Attach the drive cabinet to the floor to prevent it from toppling over The cabinet has a high center of gravity When you pull out heavy compo...

Page 15: ...you activate the automatic fault reset or automatic restart functions of the drive control program make sure that no dangerous situations can occur These functions reset the drive automatically and continue operation after a fault or supply break If these functions are activated the installation must be clearly marked as defined in IEC EN UL 61800 5 1 subclause 6 5 3 for example THIS MACHINE START...

Page 16: ... external voltages from the control circuits After you disconnect power from the drive always wait 5 minutes to let the intermediate circuit capacitors discharge before you continue 3 Protect any other energized parts in the work location against contact 4 Take special precautions when close to bare conductors 5 Measure that the installation is de energized Use a quality voltage tester If the meas...

Page 17: ...n of such devices This can cause a health hazard Remove the code labels attached to mechanical parts such as busbars shrouds and sheet metal parts before installation They may cause bad electrical connections or after peeling off and collecting dust in time cause arcing or block the cooling air flow Note When the drive is connected to the input power the motor cable terminals and the DC bus are at...

Page 18: ...djoining equipment This is necessary for the personnel safety Make sure that the conductivity of the protective earth PE conductors is sufficient and that other requirements are met See the electrical planning instructions of the drive Obey the applicable national and local regulations When using shielded cables make a 360 grounding of the cable shields at the cable entries to reduce electromagnet...

Page 19: ...These functions reset the drive automatically and continue operation after a fault or supply break If these functions are activated the installation must be clearly marked as defined in IEC EN UL 61800 5 1 subclause 6 5 3 for example THIS MACHINE STARTS AUTOMATICALLY Note The maximum number of drive power ups is five in ten minutes Too frequent power ups can damage the charging circuit of the DC c...

Page 20: ...cal safety precautions page 16 Install temporary grounding to the drive output terminals T1 U T2 V T3 W Connect the output terminals together as well as to the PE During the start up Make sure that the motor cannot run overspeed for example driven by the load Motor overspeed causes overvoltage that can damage or destroy the capacitors in the intermediate circuit of the drive Safety in operation WA...

Page 21: ...o maintenance work on the drive or create instructions for the end user of the drive concerning the installation and maintenance of the drive Read the manual before you work on the drive You are expected to know the fundamentals of electricity wiring electrical components and electrical schematic symbols Purpose of the manual This manual provides information needed for planning the installation in...

Page 22: ...e 125 Only intact units can be started up Examining the installation site page 45 Check the installation site Fasten the base of the cabinet to the floor Ambient conditions page 150 Routing the cables page 71 Route the cables Measuring the insulation page 84 Check the insulation of the supply cable the motor and the motor cable and the resistor cable if present Mechanical installation page 45 Inst...

Page 23: ...encoder interface module FEN 11 Optional resolver interface module FEN 21 Optional HTL incremental encoder interface module FEN 31 Optional Ethernet adapter module for EtherNet IP Modbus TCP and PROFINET IO protocols FENA 11 Optional Ethernet adapter module for EtherNet IP Modbus TCP and PROFINET IO protocols 2 port FENA 21 Optional Ethernet POWERLINK adapter module FEPL 01 Optional digital I O ex...

Page 24: ...Description Term Transistor transistor logic TTL Type of control unit ZCU Main circuit board ZINT Power supply board ZPOW 24 Introduction to the manual ...

Page 25: ... documents You can find manuals and other product documents in PDF format on the Internet at www abb com drives documents and with the following codes and links ACS880 04 manuals Introduction to the manual 25 ...

Page 26: ...26 ...

Page 27: ...peration principle and hardware description Contents of this chapter This chapter describes the operating principle and construction of the drive module 3 Operation principle and hardware description 27 ...

Page 28: ...erts alternating current and voltage to direct current and voltage 2 DC link DC circuit between rectifier and inverter 3 Inverter Converts direct current and voltage to alternating current and voltage 4 Brake chopper option D150 Conducts the surplus energy from the intermediate circuit of the drive to the brake resistor when necessary The chopper operates when the DC link voltage exceeds a certain...

Page 29: ... view A Back view B Drive module 1 Upper front cover 2 Lower front cover 3 Clear plastic shrouds attached 4 Heatsink cleaning hole cover 5 Flange 6 Hood 7 External control unit 8 Control panel 9 See the part descriptions below Operation principle and hardware description 29 ...

Page 30: ... the drive module entry for top cabling 3 Control panel 14 Upper back clear plastic shroud 4 Control cable clamp plate 15 Lower back clear plastic shroud 5 Cables for connecting the control unit to the drive module 16 Front clear plastic shroud 6 Fiber optic cables 17 Input power cable connection terminals op tion H370 7 Support brackets 18 Output power cable connection terminals 8 Lifting lugs 19...

Page 31: ...d DC busbars UDC UCD with option H356 2 Circuit board compartment 3 Output cable connection busbars T1 U2 T2 V2 T3 W2 and brake resistor connection busbars R and R with option D150 4 Common mode filter option E208 5 Auxiliary cooling fans 6 Heatsink 7 PE busbar 8 Cover on heatsink cleaning hole 9 Main cooling fans 10 Control unit See section Standard drive module configuration page 29 Operation pr...

Page 32: ...odule can be installed on or above the control unit 4 Memory unit see Replacing the memory unit of ZCU 14 page 126 5 I O terminal blocks see section Default I O diagram of the drive control unit ZCU 1x page 103 6 Control panel see section Connecting a control panel page 96 7 Brake resistor optional see chapter Resistor braking page 191 8 du dt or sine filter optional see chapter Filters page 199 9...

Page 33: ...pe The optional selections are given thereafter separated by plus signs The main selections are described below Not all selections are available for all types For more information refer to the ordering instructions available separately on request Basic code Description Code Product series ACS880 Type The standard delivery includes flange mounted drive module to be installed in a an enclosure IP20 ...

Page 34: ...MP 01 door mounting kit J410 DPMP 02 door mounting kit surface mounting for the panel J413 ACS AP I control panel J425 ACS DCP 11 drive connectivity panel EU variant J461 FDNA 01 DeviceNet adapter module K451 FPBA 01 PROFIBUS DP adapter module K454 FCAN 01 CANopen adapter module K457 FSCA 01 RS 485 Modbus RTU adapter module K458 FCNA 01 ControlNet adapter module K462 FECA 01 EtherCat adapter modul...

Page 35: ...ump control program N5600 Tower crane control program N5650 Control program for synchronous reluctance motors SynRM N7502 Drive application programming N8010 High speed license for 598 Hz operation N8200 Extended warranty 24 months from commissioning or 30 months from delivery P904 ATEX certified safe disconnection function Q971 FSO 21 safety functions module Q972 FSO 12 safety functions module Q9...

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Page 37: ...eatsink degree of protection IP55 in a cooling air channel or outside protected against humidity dust and chemical gases according to the ambient conditions requirements given in section Ambient conditions page 150 The control circuit compartment side of the module degree of protection IP20 is to be installed in clean air The drive module can also be installed from the heatsink with mounting brack...

Page 38: ... Installation principle 3 3 1 4 2 Cool air in max 40 C 104 F 1 Hot air out 2 Air guide 3 Air flow in the cooling air channel 4 38 Guidelines for planning the mechanical installation ...

Page 39: ...ble connection and circuit board compartment part of drive module and other equipment 3 Drive control panel with DPMP 01 mounting platform option J410 The control panel is connected to the drive module control unit inside the cabinet 4 Contactor control switch and emergency stop switch connected to the contactor control circuit inside the cabinet 5 Operating handle of the disconnector 6 Rubber gro...

Page 40: ...er cable including the protective ground conductor PE of the drive 4 Motor cable including the protective ground conductor of the drive module 12 Disconnector and fuses 5 External control cables 13 Contactor 6 Air flow 14 Input power cable connection terminals bus bars 7 Note The power cable shields can also be grounded to the drive module grounding terminals Note For option B051 When the bottom g...

Page 41: ...5 mounting platform for control panels installation guide 3AXD50000289561 DPMP 06 07 mounting platform for control panels installation guide DPMP 04 DPMP 02 DPMP 01 IP66 UL Types 3 3R and 4 when mounted inside or outside the cabinet door IP65 UL Type 12 when control panel is mounted IP20 UL Open Type when control panel is not mounted IP54 UL Type 12 when control panel is mounted IP20 UL Open Type ...

Page 42: ...cal You can install the drive module on its back Make sure that the hot cooling air which flows upwards from the module does not cause danger For other installation positions contact ABB 42 Guidelines for planning the mechanical installation ...

Page 43: ...cient cooling air flows through the module and the module cools correctly The required free space at the top and bottom of the drive module is shown below The modules can be installed side by side Min 200 mm 7 87 in Min 200 mm 7 87 in Guidelines for planning the mechanical installation 43 ...

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Page 45: ... material behind above and below the drive is non flammable There is sufficient free space around the drive for cooling maintenance and operation See the free space specifications for the drive Make sure that there are no sources of strong magnetic fields such as high current single core conductors or contactor coils near the drive A strong magnetic field can cause interference or inaccuracy in th...

Page 46: ...s see section Package drawings page 47 Cut the bands Lift the top lid If top boxes B1 are included lift them off and remove the lower lid Lift the inner and outer sheathings Remove the additional boxes and supports 46 Mechanical installation ...

Page 47: ...ts for control unit cable entry holes in the middle front cover of the drive module 6 Accessory sleeve containing 7 external control unit output cable connection terminal box B2 see below for the box contents input cable connection terminal box option H370 B3 see below for the box contents control panel door mounting kit If all options do not fit in the accessory sleeve the rest are packed in this...

Page 48: ...ud for input power cabling 13 Top clear plastic shroud 14 Entry clear plastic shroud for side input cabling 15 Clear plastic bottom shroud 1 16 Clear plastic bottom shroud 2 17 Metallic shroud 18 3AXD50000013807 1 3 4 5 6 7 8 9 10 11 13 15 17 18 16 14 12 2 Box B2 contents standard drive module configur ation Paper fill 1 Output cable connection terminal T3 W2 2 Output cable connection terminal T2 ...

Page 49: ...er of the drive module 2 Fastener for Rittal VX25 enclosure 3 Bracket for attaching the drive module from top 3AUA0000096082 The bracket brings a gap for cooling air flow and prevents the drive module screws from chafing the plate 4 Cardboard box 5 Examining the delivery Make sure that all items listed in section Moving and unpacking the unit page 45 are present Make sure that there are no signs o...

Page 50: ...50 Mechanical installation ...

Page 51: ...ounting point and mounting plate opening dimensions 1 Make an opening to the mounting plate for the drive module heatsink penetration 2 Attach the drive module flange to the mounting plate with screws 3 For UL Type 12 installations and if otherwise needed Attach the hood 6 11 11 6 6 1 3 2 Mechanical installation 51 10 ...

Page 52: ...ching the drive module by the heatsink 1 Attach the support brackets to the heatsink back 2 Attach the support brackets to the wall 1 1 2 2 2 2 Combi screw M8 20 20 N m 14 8 lbf ft 52 Mechanical installation ...

Page 53: ...can be attached on a mounting plate or onto a DIN rail Connect the fiber optic power supply and BGDR cables from the drive module to the external control unit before you attach the control unit See section Connecting the external control unit to the drive module page 91 Mechanical installation 53 10 ...

Page 54: ...n each side Make sure to use the ZCU 14 control unit mounting pattern 1 Mark the positions of the fastening screws to the wall through the mounting template 2 Attach the screws 3 Lift the control unit onto the screws and tighten the screws 3AUA0000130997 1 2 Attaching the external control unit vertically on a DIN rail 1 Attach the latch A to the back of the control unit with three screws 2 Click t...

Page 55: ... the external control unit horizontally on a DIN rail 1 Attach the latches A to the back of the control unit with three screws 2 Click the control unit to the rail as shown below B A A B B 3AUA0000130997 Mechanical installation 55 10 ...

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Page 57: ...device You must equip the drive with a main supply disconnecting device which meets the local safety regulations You must be able to lock the disconnecting device to the open position for installation and maintenance work European Union and United Kingdom To comply with European Union directives and United Kingdom regulations related to standard EN 60204 1 the disconnecting device must be one of t...

Page 58: ...r location and application 1 National Fire Protection Association 70 National Electric Code Other regions The disconnecting device must conform to the applicable local safety regulations 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...

Page 59: ...mon mode filters and insulated N end non drive end motor bearings are required Ignoring the requirements or improper installation may shorten motor life or damage the motor bearings and voids the warranty Requirements for ABB motors Pn 100 kW 134 hp See also Abbreviations page 62 Requirement for Nominal AC line voltage Motor type ABB du dt and common mode filters insulated N end motor bearings Mot...

Page 60: ...CMF N Reinforced N du dt CMF N du dt Reinforced 600 V Un 690 V cable length 150 m N CMF N Reinforced 600 V Un 690 V cable length 150 m Pn 500 kW N CMF N CMF Standard 380 V Un 690 V Form wound HX_ and AM_ Pn 500 kW N du dt CMF N du dt with voltages over 500 V CMF Check with the motor manufac turer 380 V Un 690 V Old1 form wound HX_ and modular N CMF Enamelled wire with fiber glass taping 0 V Un 500...

Page 61: ...V Random woundand form wound du dt Standard ÛLL 1300 V 420 V Un 500 V Reinforced ÛLL 1600 V 0 2 µs rise time du dt Reinforced ÛLL 1600 V 500 V Un 600 V Reinforced ÛLL 1800 V du dt Reinforced ÛLL 1800 V 600 V Un 690 V Reinforced ÛLL 2000 V 0 3 µs rise time1 1 If the intermediate DC circuit voltage of the drive is increased from the nominal level due to long term resistor braking cycles check with t...

Page 62: ... V Un 600 V N CMF N or CMF Reinforced ÛLL 1800 V N du dt CMF du dt N Reinforced ÛLL 1800 V 600 V Un 690 V N CMF N CMF Reinforced ÛLL 2000 V 0 3 µs rise time1 1 If the intermediate DC circuit voltage of the drive is increased from the nominal level due to long term resistor braking cycles check with the motor manufacturer if additional output filters are needed Abbreviations Definition Abbr Nominal...

Page 63: ...e voltage application must be selected as if the drive were supplied with 480 V Additional requirements for ABB high output and IP23 motors The rated output power of high output motors is higher than what is stated for the particular frame size in EN 50347 2001 This table shows the requirements for protecting the motor insulation and bearings in drive systems for ABB random wound motor series for ...

Page 64: ...800 V 600 V Un 690 V N CMF N CMF Reinforced ÛLL 2000 V 0 3 microsecond rise time1 1 If the intermediate DC circuit voltage of the drive is increased from the nominal level due to long term resistor braking cycles check with the motor manufacturer if additional output filters are needed Additional data for calculating the rise time and the peak line to line voltage The diagrams below show the relat...

Page 65: ...ided by the supply network The method of installation and ambient temperature affect the cable current carrying capacity Obey local regulations and laws Temperature For an IEC installation select a cable rated for at least 70 C 158 F maximum permissible temperature of conductor in continuous use For North America select a cable rated for at least 75 C 167 F Important For certain product types or o...

Page 66: ...ically constructed PE conductor and a shield or armor Yes Yes PE Symmetrical shielded or ar mored cable with three phase conductors and a shield or ar mor and separate PE conduct or cable1 1 A separate PE conductor is required if the conductivity of the shield or armor is not sufficient for the PE use Alternate power cable types Use as motor cabling and as brake resistor cabling Use as input power...

Page 67: ...e at least 1 10 of the phase conductor conductivity The effectiveness of the shield can be evaluated based on the shield inductance which must be low and only slightly dependent on frequency The requirements are easily met with a copper or aluminum shield armor The cross section of a steel shield must be ample and the shield helix must have a low gradient A galvanized steel shield has a better hig...

Page 68: ...es for your application 3 Non metallic conduit use underground is allowed however these installations inherently have an increased chance for nuisance problems due to the potential for water moisture in the conduit Water moisture in the conduit increases the likelihood of VFD faults or warnings Proper installation is required to make sure there is no intrusion of water moisture Metal conduit Coupl...

Page 69: ...f the protective earth conductor related to the phase conductor size according to IEC UL 61800 5 1 when the phase conductor s and the protective earth conductor are made of the same metal If this is not so the cross sectional area of the protective earth conductor must be determined in a manner which produces a conductance equivalent to that which results from the application of this table Minimum...

Page 70: ... mm2 as part of a multi conductor power cable Sufficient strain relief must be provided If the protective earth conductor is routed through a plug and socket or similar means of disconnection it must not be possible to disconnect it unless power is simultaneously removed Note You can use power cable shields as grounding conductors only when their conductivity is sufficient Additional grounding req...

Page 71: ...ool 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 Routing the cables General guidelines IEC Route the motor cable away from other cables Motor cables of several drives can be run in parallel installed next to each other Install the motor cable input po...

Page 72: ...guidelines North America Make sure that the installation is in accordance with national and local codes Obey these general guidelines Use separate conduits for the input power motor brake resistor optional and control cabling Use separate conduit for each motor cabling The following figure illustrates the cable routing guidelines with an example drive 72 Guidelines for planning the electrical inst...

Page 73: ...trical shielded cable or install the cabling in a metal conduit Make sure that there is a good and continuous galvanic connection in the shield conduit between drive and motor Connect the shield conduit to the protective ground terminal of the drive and the motor Separate control cable ducts Put 24 V DC and 230 V AC 120 V AC control cables in separate ducts unless the 24 V DC cable is insulated fo...

Page 74: ...s WARNING Due to the inherent operating principle and construction of circuit breakers independent of the manufacturer hot ionized gases can escape from the breaker enclosure in case of a short circuit To ensure safe use pay special attention to the installation and placement of the breakers Obey the manufacturer s instructions Protecting the motor and motor cable in short circuits The drive prote...

Page 75: ... further by feeding in additional motor and load data The most common temperature sensor types are PTC or Pt100 For more information see the firmware manual Protecting the motor against overload without thermal model or temperature sensors Motor overload protection protects the motor against overload without using motor thermal model or temperature sensors Motor overload protection is required and...

Page 76: ...e sure that the voltage does not exceed the maximum allowed voltage over the sensor 2 If there is basic insulation between the sensor and the live parts of the motor or if the insulation type is not known 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 Conn...

Page 77: ...vanic isolation between sensor connector and drive control unit connector No isolation between sensor connector and TTL encoder emulation output FEN 11 Reinforced insulation x x Galvanic isolation between sensor connector and drive control unit connector No isolation between sensor connector and TTL encoder emulation output FEN 21 Reinforced insulation x x Galvanic isolation between sensor connect...

Page 78: ...the factory The wiring of the external safety circuit and configuration of the FSO module are the responsibility of the user The FSO module reserves the standard Safe torque off STO connection of the drive control unit STO can still be utilized by other safety circuits through the FSO module See the appropriate manual for more information Code Name 3AXD50000015612 FSO 12 safety functions module us...

Page 79: ... an ATEX certified thermistor protection module for the drive option L537 or acquire and install an ATEX compliant protection relay do the necessary connections For more information see Manual code English User s manual 3AUA0000132231 ATEX certified Safe disconnection function Ex II 2 GD for ACS880 drives Q971 application guide 3AXD50000027782 FPTC 02 ATEX certified thermistor protection module Ex...

Page 80: ... 3 Open the contactor If you have the DTC motor control mode and the motor coast stop or scalar control mode selected open the contactor as follows 1 Give a stop command to the drive 2 Open the contactor WARNING When the DTC motor control mode is in use never open the output contactor while the drive controls the motor The DTC motor control operates extremely fast much faster than it takes for the...

Page 81: ... when motor is connected direct on line S42 Switching the motor power supply from drive to direct on line 1 Stop the drive and the motor with the drive control panel stop key drive in the local control mode or the external stop signal drive in the remote control mode 2 Open the main contactor of the drive with S11 3 Switch the motor power supply from the drive to direct on line with S40 4 Wait for...

Page 82: ...en switched off The relay contacts on the drive control unit are protected with varistors 250 V against overvoltage peaks In spite of this it is highly recommended that inductive loads are equipped with noise attenuating circuits varistors RC filters AC or diodes DC to minimize the EMC emission at switch off If not suppressed the disturbances may connect capacitively or inductively to other conduc...

Page 83: ...ssional do not do installation or maintenance work Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur Grounding the motor cable shield at the motor end For minimum radio frequency interference ground the cable shield 360 degrees at the cable entry of the motor terminal box 7 Electrical installation 83 11 ...

Page 84: ...sioning or maintenance work 1 Do the steps in section Electrical safety precautions page 16 before you start the work 2 Make sure that the motor cable is disconnected from the drive output terminals 3 Measure the insulation resistance between each phase conductor and the protective earth conductor Use a measuring voltage of 1000 V DC The insulation resistance of an ABB motor must be more than 100 ...

Page 85: ...onnect the EMC filter and ground to phase varistor See ACS880 frames R1 to R11 EMC filter and ground to phase varistor disconnecting instructions 3AUA0000125152 English WARNING Do not install the drive with EMC filter option E200 to a system that the filter is not suitable for This can cause danger or damage the drive WARNING Do not install the drive with the ground to phase varistor connected to ...

Page 86: ...M10 Connecting the power cables WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur 86 Electrical installation ...

Page 87: ...s used not required but recommended and the conductivity of the shield is 50 of the conductivity of the phase conductor use a separate PE cable 2a or a cable with a grounding conductor 2b 2 ABB recommends 360 grounding at the cabinet entry if a shielded cable is used Ground the other end of the input cable shield or PE conductor at the distribution board 3 ABB recommends 360 grounding at the cabin...

Page 88: ...ng the drive mod ule page 85 9 If there is a symmetrically constructed grounding conductor in the motor cable in addition to the con ductive shield connect the grounding conductor to the grounding terminal at the drive and motor ends Do not use an asymmetrically constructed motor cable Connecting its fourth conductor at the motor end increases bearing currents and causes extra wear Preparing the c...

Page 89: ...hields with cable ties Tie up the unused conductive sleeves with cable ties An example of bottom entry is shown below For top entry put the grommet upwards Power cable connection procedure For the standard drive module configuration See the step by step installation drawings in ACS880 04F quick installation guide 3AXD50000044913 multilingual For optional input power cable connection terminals and ...

Page 90: ... Connect the cable shields of the input cables and any separate ground conductors or cables to the drive module ground terminal or to the cabinet PE busbar 5 Connect the phase conductors of the input cables to terminals L1 U1 L2 V1 and L3 W1 of the drive module For the tightening torques see the technical data DC connection The UDC and UDC terminals are intended for common DC configurations of a n...

Page 91: ...afety functions module above the control unit attach the control cable clamp plate on the base of the control unit 0 7 N m 6 2 lbf in Connecting the external control unit to the drive module Control unit connection cables The cables that are delivered with the drive module for connecting the drive module and control panel to the control unit are shown below Electrical installation 91 11 ...

Page 92: ... control unit cables into the drive module Route the control unit connection cables to the drive module through the slot in the middle front cover at the front or left side First remove the plate which covers the slot Then install the rubber grommet item 2 from the accessories box Connections to the drive module 1 Connect power supply cable of the control unit to the ZPOW connector and the ground ...

Page 93: ...les inside the back frame of the control unit 2 Connect the cables to the ZBIB board terminals ZBIB SOIA V1 V10 V2 V20 ZBIB ZPOW X3 1 X3 1 X3 2 X3 2 X3 3 not used X3 3 not used ZBIB BGDR X7 STO1 X7 STO1 X8 STO2 X8 STO2 3 Connect the ZPOW cable grounding wire to the grounding terminal at the back top or bottom of the control unit Electrical installation 93 11 ...

Page 94: ...3 3 X7 X3 2 X8 BGDR SOIA X3 1 STO2 STO1 RXD TXD transmitter RXD receiver Connecting the control cables to the terminals of the external control unit 1 Route the cables to the control unit as shown below 94 Electrical installation ...

Page 95: ...th no significant voltage drop between the end points Tighten the screws to secure the connection 3 Connect the conductors to the appropriate detachable terminals of the control unit See the Default I O diagram of the drive control unit ZCU 1x page 103 Use shrink tubing or insulating tape to contain any strain strands Note Keep any signal wire pairs twisted as close to the terminals as possible Tw...

Page 96: ...A0000113618 English The maximum allowed length of the cable chain is 100 m 328 ft 1 Connect the panel to one drive using an Ethernet for example Cat 5e cable Use Menu Settings Edit texts Drive to give a descriptive name to the drive Use parameter 49 01 to assign the drive with a unique node ID number Set other parameters in group 49 if necessary Use parameter 49 06 to validate any changes The para...

Page 97: ...C is connected to the control panel the drives on the panel bus are automatically displayed in the Drive Composer PC tool With twin connectors in the control panel holder 1 2 3 1 Electrical installation 97 11 ...

Page 98: ... 02 modules OPEN TERMINATED 1 1 2 2 OPEN TERMINATED 3 Connecting a PC WARNING Do not connect the PC directly to the control panel connector of the control unit as this can cause damage 98 Electrical installation ...

Page 99: ...odules WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur Pay attention to the free space required by the cabling or terminals coming to the option modules 1 Repeat the steps described in Electrical safety precautions page 16 2 Pull out the lock a Note The location of the lock depends on the module type 3 Install the module to ...

Page 100: ...b a 6 Connect the wiring to the module Obey the instructions given in the documentation of the module 100 Electrical installation ...

Page 101: ...e 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 8 Control unit of the drive 101 ...

Page 102: ...nit When the ZCU is controlling a supply unit de energizing the inputs will stop the unit but will not constitute a true safety function XSTO Connection for FSO xx safety functions module inverter unit only X12 Control panel connection X13 Option slot 1 X202 Option slot 2 X203 Option slot 3 X204 Memory unit connection memory unit inserted in the drawing X205 Voltage Current selection jumpers J1 J2...

Page 103: ...AI2 Current I voltage U selection jumper for AI1 J1 Current I voltage U selection jumper for AI2 J2 XAO Analog outputs Motor speed rpm AO1 AO1 AGND AO2 AGND 1 2 3 4 0 22 mA RL 500 ohm AGND Motor current 0 22 mA RL 500 ohm AO2 AGND XD2D Drive to drive link Master follower drive to drive or embedded fieldbus connection 2 B 1 2 3 B A BGND 4 Shield A BGND Shield Drive to drive link termination 2 J3 XR...

Page 104: ...ted by jumper Change of setting requires reboot of control unit 2 See section The XD2D connector page 106 3 See section DIIL input page 106 4 Total load capacity of these outputs is 4 8 W 200 mA at 24 V minus the power taken by DIO1 and DIO2 5 Determines whether DICOM is separated from DIOGND ie common reference for digital inputs floats in practice selects whether the digital inputs are used in c...

Page 105: ... drop between the end points See the firmware manual of the inverter unit for parameter settings 1 24V DI6 t t t t t t 1 6 PTC thermistors connected in series 1 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 WARNING Make sure that the voltag...

Page 106: ...stop the unit when the input signal is lost Note This input is not SIL or PL certified The XD2D connector The XD2D connector provides an RS 485 connection that can be used for basic master follower communication with one master drive and multiple followers fieldbus control through the embedded fieldbus interface EFB or drive to drive D2D communication implemented by application programming See the...

Page 107: ...off function page 171 Note The XSTO input only acts as a true Safe torque off input on the inverter control unit De energizing the IN1 and or IN2 terminals of other units supply DC DC converter or brake unit will stop the unit but not constitute a true safety function FSO safety functions module connection X12 Refer to the applicable FSO module user s manual Control unit of the drive 107 ...

Page 108: ... size 0 5 2 5 mm2 22 12 AWG Digital inputs outputs DIO1 and DIO2 XDIO 1 and XDIO 2 As inputs 24 V logic levels 0 5 V 1 15 V Rin 2 0 kohm Filtering 1 ms Input output mode selection by para meters As outputs Total output current from 24VD is limited to 200 mA DIO1 can be configured as a frequency input 0 16 kHz with hardware filter ing of 4 microseconds for 24 V level square wave signal sinusoidal o...

Page 109: ...fe torque off connection XSTO Input voltage range 3 30 V DC Logic levels 0 5 V 1 17 V Note For the unit to start both connections must be 1 This applies to all control units including drive inverter supply brake DC DC converter etc control units but true Safe torque off functionality is only achieved through the XSTO connector of the drive inverter control unit Current consumption 66 mA continuous...

Page 110: ...L 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 GND 2 IN1 3 IN2 4 Common mode voltage between channels 30 V Ground selector J6 settings All digital inputs share a common ground DICOM connected to DIOGND This is the default setting Ground of digital inputs DI1 DI5 and DIIL DICOM is isolated from DIO signal ground DIOGND Isolation voltage 50 ...

Page 111: ...stallation commissioning or maintenance work WARNING Stop the drive and do the steps in section Electrical safety precautions page 16 before you start the work Make sure that The ambient operating conditions meet the drive ambient conditions specification and enclosure rating IP code The supply voltage matches the nominal input voltage of the drive See the type designation label The insulation res...

Page 112: ...ened to the correct torque Grounding has also been measured according to the regulations The motor cable is connected to the correct terminals the phase order is correct and the terminals are tightened to the correct torque The motor cable is routed away from other cables No power factor compensation capacitors are connected to the motor cable If an external brake resistor is connected to the driv...

Page 113: ... the installation of the drive module has been checked according to the checklist in chapter Installation checklist and that the motor and driven equipment are ready for start 3 Perform the start up tasks instructed by the cabinet installer of the drive module 4 Switch the power on setup the drive control program and perform the first start of the drive and motor See Quick start up guide for ACS88...

Page 114: ...s in explosive atmospheres See also ACS880 drives with ABB motors in explosive atmospheres 3AXD50000019585 English 6 For drive modules in which the Safe torque off function is in use Test and validate the operation of the Safe torque off function See Validation test procedure page 179 7 For drive modules with an FSO xx safety functions module options Q972 and Q973 Test and validate the operation o...

Page 115: ...odule with option J410 When the LED is lit Color LED Where Control unit is powered and 15 V is supplied to the control panel Green POWER Control panel mounting plat form Drive in fault state Red FAULT Warning and fault messages See the firmware manual for the descriptions causes and remedies of the control program warning and fault messages 11 Fault tracing 115 ...

Page 116: ...116 ...

Page 117: ...nance schedule is available on the Internet https new abb com drives services maintenance preventive maintenance For more information consult your local ABB Service representative www abb com searchchannels Description of symbols Description Action Inspection visual inspection and maintenance action if needed I Performance of on off site work commissioning tests measurements or other work P Replac...

Page 118: ...I I I I I I I I I I Tightness of terminals I I I I I I I I I I I I I Ambient conditions dustiness moisture corrosion temperat ure I I I I I I I I I I I I I Cleaning of heatsinks Funtional safety I See the maintenance information of the safety function Safety function test 20 years Safety component expiry Mis sion time TM Note Maintenance and component replacement intervals are based on the assumpt...

Page 119: ...arges which can damage circuit boards 1 Stop the drive and do the steps in section Electrical safety precautions page 16 before you start the work 2 Open the cabinet door 3 Clean the interior of the cabinet Use a vacuum cleaner and a soft brush 4 Clean the air inlets of the fans and air outlets of the modules top 5 Clean the air inlet gratings if any on the door 6 Close the door Heatsink The drive...

Page 120: ...ates static discharges which can damage circuit boards 1 Stop the drive and do the steps in section Electrical safety precautions page 16 before you start the work 2 Undo the attaching screws of the cover plate on the service opening 3 Remove the plate 4 Carefully blow clean compressed air not humid or oily upwards from the opening and at the same time vacuum from the top of the drive module Preve...

Page 121: ...fied spare parts Replacing the circuit board compartment cooling fans WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur 1 Stop the drive and do the steps in section Electrical safety precautions page 16 before you start the work 2 Remove the cover 3 Undo the fastening screw of the fan enclosure 4 Unplug the power supply cable ...

Page 122: ...4 3 2 122 Maintenance ...

Page 123: ... 1 Stop the drive and do the steps in section Electrical safety precautions page 16 before you start the work 2 If motor cables are connected to the output terminals disconnect them 3 Undo the mounting screws of the fan cassette cover and remove the cover 4 Disconnect the power supply wires of the fans 5 Pull the fan cassette out 6 Install the new fan cassette in reverse order to the above 7 Reset...

Page 124: ...the fans see the previous page 6 Install the new fan cassette in reverse order to the above 7 Reset the counter if used in group 5 in the primary control program 2 3 4 Replacing the standard drive module WARNING Obey the safety instructions of the drive If you ignore them injury or death or damage to the equipment can occur Note The replacement module must be of the same type as the original modul...

Page 125: ...t trip If you think that any capacitors in the drive have failed contact ABB Reforming the capacitors The capacitors must be reformed if the drive has not been powered either in storage or unused for a year or more The manufacturing date is on the type designation label For information on reforming the capacitors refer to Capacitor reforming instructions 3BFE64059629 English Control panel See ACS ...

Page 126: ...it This can take several minutes WARNING Do not remove or insert the memory unit when the control unit is powered 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 16 before you start the work 2 Pull the clip of the memory forward R9 R10 R11 3 Take...

Page 127: ...SIL PL classification of the safety function The following options exist Renewal of the whole drive and all optional functional safety module s and components Renewal of the components in the safety function circuit In practice this is economical only with larger drives that have replaceable circuit boards and other components such as relays Note that some of the components may already have been r...

Page 128: ...128 ...

Page 129: ...om ABB for the drive module installation Note This chapter lists only the installation accessories available from ABB All other parts must be sourced from a third party by the system integrator Output du dt filters See section du dt filters page 199 Sine filters See section Sine filters page 200 13 Ordering information 129 ...

Page 130: ...AXD50000019544 1 Full size cable connection terminals for output power cables 3AXD50000019538 2 For frame R11 IP20 shrouds for covering the input and motor cabling area 1 The drive module is delivered with full size cable connection terminals for output power cables as standard They can be excluded with option 0H371 2 The drive module is delivered with IP20 shrouds for covering the input and motor...

Page 131: ...nal use PHd IHd PLd ILd Sn Pn I2 Imax_start Imax I1 kW A kW A kVA kW A A A A Un 400 V 200 361 250 485 349 250 504 671 560 504 R11 504A 3 250 429 315 575 405 315 584 828 730 584 R11 584A 3 250 477 355 634 450 355 649 954 730 649 R11 649A 3 315 566 400 715 502 400 725 1100 1020 725 R11 725A 3 355 625 450 810 568 450 820 1100 1020 820 R11 820A 3 400 725 500 865 610 500 880 1100 1100 880 R11 880A 3 Un...

Page 132: ...5 862 710 721 1100 820 721 R11 721A 7 3AXD00000588487 UL NEC RATINGS Output ratings Max current Input current Frame size ACS880 04F Heavy duty use Light duty use App power PHd IHd PLd ILd Sn Imax_start Imax I1 hp A hp A kVA A A A Un 480 V 671 560 459 R11 459A 5 300 361 400 483 435 671 560 502 R11 502A 5 350 414 450 573 504 828 730 582 R11 582A 5 400 477 500 623 549 954 730 634 R11 634A 5 450 566 6...

Page 133: ...oad for 1 minute every 5 minutes Continuous rms output current allowing 44 overload for 1 minute every 5 minutes Typical motor power for heavy duty use PHd Note 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 power ratings apply to most IEC 34 motors at the nominal voltage of the drive ABB recommends to ...

Page 134: ...nt for every added 100 m 328 ft For example the derating factor for 1500 m 4921 ft is 0 95 The maximum permitted installation altitude is given in the technical data If the surrounding air temperature is less than 40 C 104 F the derating can be reduced by 1 5 percentage points for every 1 C 1 8 F reduction in temperature A few altitude derating curves are shown below 134 Technical data ...

Page 135: ...ngs in the drive control program Enabling special settings in the drive control program can require output current derating Ex motor sine filter low noise Table below gives the deratings for these cases drive is used with an ABB motor for explosive atmospheres Ex and EX motor in parameter 95 15 Special HW settings is enabled sine filter given in the selection table in section Sine filters page 200...

Page 136: ... 530 400 560 419 553 400 579 634A 5 362 428 315 462 507 620 450 637 522 641 450 657 715A 5 400 490 355 530 560 710 500 730 576 734 500 753 820A 5 410 510 400 550 560 710 500 730 594 747 500 768 880A 5 Un 690 V 157 222 200 232 204 293 250 303 217 300 250 310 329A 7 200 250 250 260 260 330 315 340 276 338 315 347 369A 7 236 280 250 290 300 350 355 360 315 368 355 377 429A 7 238 261 250 270 308 349 3...

Page 137: ...ut frequency Deratings with selection High speed mode of parameter 95 15 Special HW settings ACS880 04F Maximum output frequency 120 Hz output frequency Heavy duty use Light duty use Nominal use Maxim um fre quency Heavy duty use Light duty use Nominal use Fre quency IHd ILd Pn I2 fmax IHd ILd Pn I2 f A A kW A Hz A A kW A Hz Un 400 V 290 370 200 390 500 361 485 250 504 120 504A 3 311 419 250 437 5...

Page 138: ...frequency f Maximum output frequency with High speed mode fmax Nominal voltage of the drive Un Continuous rms output current No overload capability at 40 C 104 F I2 Typical motor power in no overload use Pn Continuous rms output current allowing 10 overload for 1 minute every 5 minutes ILd Continuous rms output current allowing 50 overload for 1 minute every 5 minutes IHd Continuous rms output cur...

Page 139: ...20 11000 820A 5 3 170M6019 690 3900000 1600 880 11000 880A 5 Un 690 V 3 170M6011 690 300000 700 329 3600 329A 7 3 170M6013 690 670000 900 369 5600 369A 7 3 170M6014 690 945000 1000 429 6500 429A 7 3 170M6015 690 1300000 1100 470 7800 470A 7 3 170M6016 690 1950000 1250 522 9100 522A 7 3 170M6017 690 2450000 1400 590 10200 590A 7 3 170M6018 690 3100000 1500 650 10500 650A 7 3 170M6018 690 3100000 15...

Page 140: ...n example Drive ACS880 04F 715A 5 Supply voltage 500 V Transformer rated power Sn 5000 kVA rated voltage drive supply voltage UN 480 V transformer impedance zk 10 Supply cable length 170 m resistance length 0 125 ohm km reactance length 0 074 ohm km 480 V 2 5000 kVA 4 61 mohm Zk zk UN 2 SN 0 1 m 0 125 ohm km 21 25 mohm Rc 170 m 0 074 ohm km 12 58 mohm Xc 170 500 V 2 21 25 mohm 2 4 61 mohm 12 58 mo...

Page 141: ... installation are not included in the base drive configuration and must be provided by others 2 Fuses with a higher current rating than specified must not be used 3 The UL listed fuses recommended by ABB are the required branch circuit protection per NEC Circuit breakers listed in section Circuit breakers UL are also acceptable as branch circuit protection 4 The recommended size or smaller UL list...

Page 142: ...0B051 E208 0H371 C217 withoutshrouds full sizeoutputpowercableconnection terminals and with wall mounting kit instead of flange Weight Depth4 Width Height3 Frame size lb kg in mm in mm in mm 489 222 15 94 405 24 41 620 64 84 1647 R11 1 Height of standard drive module with hood 1930 mm 75 98 in 2 Depth of standard drive module with hood 556 mm 21 89 in 3 Height with optional selection 0B051 0H371 f...

Page 143: ... Package dimensions Package dimensions without IP shroud kit Technical data 143 ...

Page 144: ...CS880 04F 715A 5 75 9981 120 1400 R11 ACS880 04F 820A 5 75 10956 120 1400 R11 ACS880 04F 880A 5 Un 690 V 75 3266 120 1400 R11 ACS880 04F 329A 7 75 3725 120 1400 R11 ACS880 04F 369A 7 75 4539 120 1400 R11 ACS880 04F 429A 7 75 5198 120 1400 R11 ACS880 04F 470A 7 75 5984 120 1400 R11 ACS880 04F 522A 7 75 7115 120 1400 R11 ACS880 04F 590A 7 75 8289 120 1400 R11 ACS880 04F 650A 7 75 9628 120 1400 R11 A...

Page 145: ...3 120 2 3 120 369A 7 2 500 MCM or 3 250 MCM 2 350 MCM or 3 4 0 2 3 120 2 3 95 429A 7 2 600 MCM or 3 300 MCM 2 400 MCM or 3 4 0 3 3 150 3 3 95 470A 7 2 700 MCM or 3 350 MCM 2 500 MCM or 3 250 MCM 3 3 185 3 3 120 522A 7 3 500 MCM or 4 300 MCM 2 600 MCM or 3 300 MCM 3 3 185 3 3 150 590A 7 3 500 MCM or 4 300 MCM 2 700 MCM or 3 350 MCM 3 3 240 3 3 150 650A 7 3 600 MCM or 4 400 MCM 3 500 MCM or 4 300 MC...

Page 146: ...80 500 V AC ACS880 04F xxxx 7 drives 525 690 V AC 3 phase 10 15 This is indic ated in the type designation label as typical input voltage levels 3 525 600 690 V AC TN grounded and IT ungrounded systems Network type Maximum allowable prospective short circuit current is 65 kA when protected by the fuses given in the fuse table Rated conditional short circuit current Icc IEC 61439 1 The drive is sui...

Page 147: ...crease depends on the motor cable length and charac teristics Contact ABB for more information Note that a sine filter optional at the drive output also causes a voltage decrease For drive modules without du dt filter 2 m 7 ft from each drive module to the motor or 4 m 13 ft between the drive modules possible only with special precautions see section du dt filters page 199 The motor cabling must b...

Page 148: ...34A 5 21 0 906 ACS880 04F 715A 5 21 0 1033 ACS880 04F 820A 5 21 0 1120 ACS880 04F 880A 5 Un 690 V 4 7 428 ACS880 04F 329A 7 4 7 480 ACS880 04F 369A 7 4 7 558 ACS880 04F 429A 7 9 3 611 ACS880 04F 470A 7 9 3 679 ACS880 04F 522A 7 9 3 767 ACS880 04F 590A 7 9 3 845 ACS880 04F 650A 7 9 3 937 ACS880 04F 721A 7 Control panel type ACS AP W assistant control panel with Bluetooth connection Efficiency Appro...

Page 149: ...sign tool https ecodesign drivesmotors abb com Protection classes for module IP20 standard Degrees of protection IEC EN 60529 IP00 option 0B051 Heatsink IP55 UL Open Type Enclosure types UL 50 50E Heatsink UL Type 12 III Overvoltage category IEC EN 60664 1 I Protective class IEC EN 61800 5 1 Technical data 149 ...

Page 150: ...midity No condensation allowed Maximum allowed relative humidity is 60 in the presence of corrosive gases IEC 60721 3 2 1997 IEC 60721 3 1 1997 IEC EN 60721 3 3 2002 Contamination levels Class 2C2 Class 1C2 Class 3C2 Chemical gases Class 2S2 Class 1S3 packing must support this otherwise 1S2 Class 3S2 No conductive dust allowed Solid particles 2 Pollution degree IEC EN 60664 1 60 106 kPa 0 6 1 05 a...

Page 151: ...Cardboard Kraft paper PP straps PE foil bubble wrap Plywood wood only for heavy components Materials vary according to the item type size and shape Typical package consists of a cardboard box with paper filling or bubble wrap ESD safe packing materials are used for printed circuit boards and similar items Materials of manuals Printed product manuals are recyclable paper Product manuals are availab...

Page 152: ... speed electrical power drive systems Part 3 EMC requirements and specific test methods IEC 61800 3 2004 A1 2011 EN 61800 3 2004 A1 2012 Standard for Adjustable Speed Electrical Power Drive Systems Part 5 1 Safety Requirements Electrical Thermal and Energy UL 61800 5 1 First edi tion General Requirements Canadian Electrical Code Part II CSA C22 2 No 0 10 Adjustable speed drives CSA C22 2 No 274 17...

Page 153: ...ld enter the recycling system at an appropriate collection point and not placed in the normal waste stream UKCA UK Conformity Assessed mark Product complies with the applicable United Kingdom s legislation Statutory Instruments Marking is required for products being placed on the market in Great Britain England Wales and Scotland EMC compliance IEC EN 61800 3 Definitions EMC stands for Electromagn...

Page 154: ...ter E200 or E201 2 The motor and control cables are selected as specified in the hardware manual 3 The drive is installed according to the instructions given in the hardware manual 4 Maximum motor cable length is 100 meters WARNING A drive of category C3 is not intended to be used on a low voltage public network which supplies domestic premises Radio frequency interference is expected if the drive...

Page 155: ...280 English 3 The motor and control cables are selected and routed according to the electrical planning guidelines of the drive The EMC recommendations are obeyed 4 The drive is installed according to its installation instructions The EMC recommendations are obeyed WARNING A drive of category C4 is not intended to be used on a low voltage public network which supplies domestic premises Radio frequ...

Page 156: ... 600 V maximum when protected by the UL fuses given elsewhere in this chapter The cables located within the motor circuit must be rated for at least 75 C in UL compliant installations The input cable must be protected with fuses These protective devices provide branch circuit protection in accordance with the national regulations National Electrical Code NEC or Canadian Electrical Code Obey also a...

Page 157: ...tablish and maintain any appropriate measures such as but not limited to the installation of firewalls prevention of physical access application of authentication measures encryption of data installation of anti virus programs etc to protect the product the network its system and the interface against any kind of security breaches unauthorized access interference intrusion leakage and or theft of ...

Page 158: ...158 ...

Page 159: ...Dimension drawings Contents of this chapter This chapter contains dimension drawings of the drive modules 15 Dimension drawings 159 ...

Page 160: ...Standard configuration IP20 UL Type Open 160 Dimension drawings ...

Page 161: ...Drive module with options E208 and H370 IP20 UL Type Open Dimension drawings 161 ...

Page 162: ...Drive module with options 0B051 E208 0H371 IP00 UL Type Open 162 Dimension drawings ...

Page 163: ...Drive module with options 0B051 E208 0H371 C217 IP00 UL Type Open Dimension drawings 163 ...

Page 164: ...Drive module with options 0B051 0H371 IP00 UL Type Open 164 Dimension drawings ...

Page 165: ...Mounting plate opening 3AXD50000038119 Dimension drawings 165 ...

Page 166: ...3AXD50000038119 166 Dimension drawings ...

Page 167: ...External control unit 3AXD50000011687 Dimension drawings 167 ...

Page 168: ...168 ...

Page 169: ...an example circuit diagram for a cabinet installed drive module Example circuit diagram This diagram is an example for the main wiring of a drive cabinet Note that the diagram includes components which are not included in a basic delivery 16 Example circuit diagram 169 ...

Page 170: ...2 5 Switch fuse disconnector1 6 Common mode filter3 7 du dt filter or sine filter2 8 Drive module 9 Input and output signals 10 Alarm 11 Supply 12 360 degree grounding recommended 13 Brake resistor2 14 1 Must be acquired by the customer 2 Optional can be installed by the customer 3 Optional can be selected with an option code 170 Example circuit diagram ...

Page 171: ...ectrical parts of the machinery without switching off the power supply to the drive When activated the Safe torque off function disables the control voltage for the power semiconductors of the drive output stage thus preventing the drive from generating the torque required to rotate the motor If the motor is running when Safe torque off is activated it coasts to a stop The Safe torque off function...

Page 172: ... related systems IEC 61508 2 2010 Functional safety Safety instrumented systems for the process in dustry sector IEC 61511 1 2017 Adjustable speed electrical power drive systems Part 5 2 Safety requirements Functional IEC 61800 5 2 2016 EN 61800 5 2 2007 Safety of machinery Functional safety of safety related electrical electronic and programmable electronic control systems IEC 62061 2021 EN 62061...

Page 173: ...ommends double shielded twisted pair cable Maximum cable lengths 300 m 1000 ft between activation switch K and drive control unit 60 m 200 ft between multiple drives 60 m 200 ft between external power supply and first control unit Note A short circuit in the wiring between the switch and an STO terminal causes a dangerous fault Therefore it is recommended to use a safety relay including wiring dia...

Page 174: ... Single drive internal power supply Dual channel connection 24 V OUT SGND IN2 UDC UDC K IN1 1 2 3 4 Drive 1 Control unit 2 Control logic 3 To motor 4 Activation switch K 174 The Safe torque off function ...

Page 175: ...ng any potential failure modes for the wiring For example use shielded cable For measures for fault exclusion of wiring see eg EN ISO 13849 2 2012 table D 4 Drive 1 Control unit 2 Activation switch Note A single channel activation switch can limit the SIL PL capability of the safety function to a lower level than the SIL PL capability of the STO function of the drive K The Safe torque off function...

Page 176: ... Multiple drives Internal power supply 24 V OUT SGND IN1 IN2 OUT SGND IN1 IN2 OUT SGND IN1 IN2 K XSTO XSTO XSTO 1 1 1 2 2 2 Drive 1 Control unit 2 Activation switch K 176 The Safe torque off function ...

Page 177: ...External power supply OUT SGND IN1 IN2 OUT SGND IN1 IN2 OUT SGND IN1 IN2 24 V 24 V DC K XSTO XSTO XSTO 1 2 1 2 1 2 Drive 1 Control unit 2 Activation switch K The Safe torque off function 177 ...

Page 178: ... this occurs Note This parameter does not affect the operation of the STO function itself The STO function will operate regardless of the setting of this parameter a running drive will stop upon removal of one or both STO signals and will not start until both STO signals are restored and all faults reset Note The loss of only one STO signal always generates a fault as it is interpreted as a malfun...

Page 179: ...reports Signed validation test reports must be stored in the logbook of the machine The report shall include documentation of start up activities and test results references to failure reports and resolution of failures Any new validation tests performed due to changes or maintenance shall be logged into the logbook Validation test procedure After wiring the Safe torque off function validate its o...

Page 180: ...ribed above in testing the operation when the motor is stopped Close the STO circuit Reset any active faults Restart the drive and check that the motor runs normally Test the operation of the failure detection of the drive The motor can be stopped or running Open the 1st input channel of the STO circuit If the motor was running it should coast to a stop The drive generates an FA81 fault indication...

Page 181: ...e when the power is restored it is possible that the drive starts without a fresh start command Take this into account in the risk assessment of the system WARNING Permanent magnet or synchronous reluctance SynRM motors only In case of a multiple IGBT power semiconductor failure the drive can produce an alignment torque which maximally rotates the motor shaft by 180 p degrees with permanent magnet...

Page 182: ...commendation of Use CNB M 11 050 published by the European co ordination of Notified Bodies concerning dual channel safety related systems with electromechanical outputs When the safety integrity requirement for the safety function is SIL 3 or PL e cat 3 or 4 the proof test for the function must be performed at least every month When the safety integrity requirement for the safety function is SIL ...

Page 183: ...nd input channel of the STO circuit If the motor was running it should coast to a stop The drive generates an FA82 fault indication see the firmware manual Close the STO circuit Reset any active faults Restart the drive and check that the motor runs normally Document and sign the test report to verify that the safety function has been tested according to the procedure Simplified proof test procedu...

Page 184: ...ion function is performed and the drive trips on an FA81 or FA82 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 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 diagn...

Page 185: ...ety data The safety data for the Safe torque off function is given below Note The safety data is calculated for redundant use and applies only if both STO channels are used The Safe torque off function 185 ...

Page 186: ...D a PFD avg PFH T 1 20 a 1 h PL SC SIL Frame size Simplified proof test Perfect proof test T 1 5 or 10 a T 1 10 a T 1 5 a 7 50E 09 7 70E 07 7 50E 11 20 80 1 3 99 65 90 18327 3 20E 04 1 60E 04 8 00E 05 3 65E 09 e 3 3 R11 3AXD10001609376 A 186 The Safe torque off function ...

Page 187: ...trol system in respect of their resistance to faults and their subsequent behavior in the fault condition and which is achieved by the structural arrangement of the parts fault detection and or by their reliability The categories are B 1 2 3 and 4 EN ISO 13849 1 Cat Common cause failure EN ISO 13849 1 CCF Diagnostic coverage EN ISO 13849 1 DC Hardware fault tolerance IEC 61508 HFT Mean time to dan...

Page 188: ... be followed to keep the PL capability EN ISO 13849 valid IEC 61508 6 T1 See also section Maintenance 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 TM values given cannot be regarded as a guarantee or warranty EN ISO 13849 1 TM Dangerous failure rate per hour of the diagnostics...

Page 189: ...SO 21 and FSE 31 option modules Q972 and L521 encoder supported Safe motor temperature with FPTC 01 thermistor protection module L536 Safe stop 1 SS1 t with FSPS 21 PROFIsafe module Q986 are in conformity with all the relevant safety component requirements of EU Machinery Directive 2006 42 EC when the listed safety functions are used for safety component functionality Adjustable speed electrical p...

Page 190: ...Safe stop 1 Safe stop emergency Safely limited speed Safe maximum speed Safe brake control Prevention of unexpected start up with FSO 12 option module Q973 encoderless Safe stop 1 Safe stop emergency Safely limited speed Safe maximum speed Safe brake control Safe speed monitor Safe direction Prevention of unexpected start up with FSO 21 and FSE 31 option modules Q972 and L521 encoder supported Saf...

Page 191: ... as add on kits The brake chopper handles the energy generated by a decelerating motor The extra energy increases the DC link voltage 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 t...

Page 192: ...diated emissions inductive load and voltage peaks over the 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 Protecting the resistor cable against short circuits The input fuses of the drive will also protect the resistor cable ...

Page 193: ...ed according to the instructions and the internal brake chopper is in use The drive will disable power flow through the input bridge if the chopper remains conductive in a fault situation but the charging resistor may fail Note If an external brake chopper outside the drive module is used ABB always requires a main contactor Selecting the default brake system components 1 Calculate the maximum pow...

Page 194: ...n Rmin This will cause overcurrent that will damage the brake chopper and the drive 2 make sure that the resistance of the custom resistor does not restrict the braking capability needed ie where Maximum power generated by the motor during braking Pmax Drive intermediate DC circuit voltage UDC 1 35 1 2 415 V DC when supply voltage is 380 415 V AC 1 35 1 2 500 V DC when supply voltage is 440 500 V ...

Page 195: ... Connection diagram See section Power cable connection diagram page 87 Connection procedure Connect the resistor cables to the R and R terminals in the same way as the other power cables If a shielded three conductor cable is used cut the third conductor and ground the twisted shield of the cable protective earth conductor of the resistor assembly at both ends Wire the thermal switch to a digital ...

Page 196: ...o the brake resistor overload protection parameters 43 08 and 43 09 according to the application 3 Set parameter 31 02 External event 1 type to Fault 4 Set parameter 43 07 Brake chopper run enable to Other bit and select from parameter 10 01 DI status the digital input where the thermal switch of the brake resistor is wired 5 Set the resistance value of the resistor to parameter 43 10 Brake resist...

Page 197: ...UR200F500 0 7 400 820A 5 40 16200 0 9 3 SAFUR200F500 0 7 400 880A 5 Un 690 V 13 3600 2 7 SAFUR200F500 2 2 285 329A 7 13 3600 2 7 SAFUR200F500 2 2 285 369A 7 13 3600 2 7 SAFUR200F500 2 2 285 429A 7 18 7200 2 0 2 SAFUR125F500 2 0 350 470A 7 18 7200 2 0 2 SAFUR125F500 2 0 350 522A 7 18 7200 2 0 2 SAFUR125F500 1 8 400 590A 7 18 7200 2 0 2 SAFUR125F500 1 8 400 650A 7 18 7200 2 0 2 SAFUR125F500 1 8 400 ...

Page 198: ...t of the resistors is 555 seconds Dimensions weights and ordering codes 234 300 1320 Ø 7 345 1270 ABB ordering code Weight Brake resistor type 68759285 25 kg 55 lb SAFUR125F500 68759340 30 kg 66 b SAFUR200F500 Terminals and cable entry data See section Terminal and entry data for the power cables page 146 198 Resistor braking ...

Page 199: ...filter type Drive module type ACS880 04F du dtfilter type Drive module type ACS880 04F Un 690 V Un 500 V Un 400 V FOCH0610 70 329A 7 FOCH0610 70 459A 5 FOCH0610 70 504A 3 FOCH0610 70 369A 7 FOCH0610 70 502A 5 FOCH0610 70 584A 3 FOCH0610 70 429A 7 FOCH0610 70 582A 5 FOCH0610 70 649A 3 FOCH0610 70 470A 7 FOCH0610 70 634A 5 FOCH0875 70 725A 3 FOCH0610 70 522A 7 FOCH0875 70 715A 5 FOCH0875 70 820A 3 F...

Page 200: ...00 V Un 400 V NSIN0485 6 329A 7 NSIN0485 6 459A 5 NSIN0900 6 504A 3 NSIN0485 6 369A 7 NSIN0900 6 502A 5 NSIN0900 6 584A 3 NSIN0485 6 429A 7 NSIN0900 6 582A 5 NSIN0900 6 649A 3 NSIN0485 6 470A 7 NSIN0900 6 634A 5 NSIN0900 6 725A 3 NSIN0485 6 522A 7 NSIN0900 6 715A 5 NSIN0900 6 820A 3 NSIN0900 6 590A 7 NSIN0900 6 820A 3 NSIN0900 6 880A 3 NSIN0900 6 650A 7 NSIN0900 6 880A 5 NSIN0900 6 721A 7 NSIN0900...

Page 201: ... by navigating to www abb com searchchannels Product training For information on ABB product training navigate to new abb com service training Providing feedback on ABB manuals Your comments on our manuals are welcome Navigate to new abb com drives manuals feedback form Document library on the Internet You can find manuals and other product documents in PDF format on the Internet at www abb com dr...

Page 202: ...www abb com drives 3AXD50000034664D Copyright 2022 ABB All rights reserved Specifications subject to change without notice 3AXD50000034664 Rev D EN 2022 08 31 ...

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